Line balancing - What is Line in Apparel Manufacturing

Line balancing © SOFT Student Handouts, By, Sunil Talekar, Faculty, SOFT-Pune What is line in apparel manufacturing? Line: an assembly line composed of several work stations, at which specific operations are performed. To work effectively, with no work pile-ups between stations, the line must be balanced, e.g. work must get through each workstation in roughly the same amount of time. What i s Li ne Pl anni ng? Line planning is scheduling and allocating of orders to production lines according to product setting (product is being made in the line) and due dates of production completion. A line plan defines when a style is going to be loaded to the line, how many pieces to be expected (target) from the line and when order to be completed. For example, please refer to the following Table-1, where a simple line planning has been shown in spread sheet. During booking orders or allocating orders to the production line, planners must check what is running on the line and how many days it will take to complete the Running style. Benefit of Line planning: It helps production manager as well as line supervisor with information such as what is the daily production target for line. They set their line (machines and manpower) accordingly. Line plan also provides information such as how many days style would run, what is the next style going to be loaded? Line plan Line 1 Line 2 Total Date Daily Prod. Cumm Prod. Daily Prod. Cumm Prod. Daily Prod. 1-Dec loading #2341A, Qty -3000 pieces 300 1200 300 2-Dec 200 200 300 1500 500 3-Dec 250 450 300 1800 550 4-Dec 400 850 200 2000 600 5-Dec 400 1250 loading #Polo , Qty -1500 pieces 400 6-Dec 400 1650 0 0 400 7-Dec 400 2050 100 100 500 8-Dec 400 2450 300 400 700 9-Dec 400 2850 350 750 750 10-Dec 150 3000 350 1100 500 11-Dec loading #432K, Qty -5500 pieces 400 1500 400 12-Dec 100 100 loading #YK45, Qty -4500 pieces 100 13-Dec 250 350 200 200 450 14-Dec 500 850 250 450 750 15-Dec 500 1350 400 850 900 16-Dec 500 1850 400 1250 900 17-Dec 500 2350 400 1650 900 18-Dec 500 2850 400 2050 900 19-Dec 500 3350 400 2450 900 20-Dec 500 3850 400 2850 900 21-Dec 500 4350 400 3250 900 22-Dec 500 4850 400 3650 900 23-Dec 150 5000 400 4050 550 )Daily Prod. – Daily production or line output Cumm Prod. – Cumulative production of the style till date) LINE BALANCING  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 ”  LINE BALANCING (Process Organization) It is a system where you meet the production expectations and you can find the same amount of work in process in every operation at any point in the day. Why Line balancing… @ the main job in line balancing is to eliminate or reduce wip (work in process) at bottleneck operations. @ keeps inventory costs low, resulting in higher net income @ allows operator to work all day long giving an opportunity to earn more money and increases his/her work efficiency @ keeps the prices low which turns into repeat sales @ means better production planning Line balancing in apparel manufacturing 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 .         Line Balancing tools                     Line balancing in apparel manufacturing Steps to a Balanced line 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. 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[...]... cost-benefitsperformers.additional higher use layout of putting Improve workstation high the line and improve methods Do extra machine into work at bottleneck operations Reduce cycle time using work aids and attachments Line balancing in apparel manufacturing All in all… From Imbalanced line To Balanced line 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.. .Line balancing in apparel manufacturing St e p 3 : Ta r g e t s e t t i ng 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.  ep I de... of eliminating bottlenecks from the line Club operations where possible Give the operator Shuffle operators Operations content low work another operation with less workthat haveconsidering Add moreuse low performer while work contentAlso bottleneck operations content operators at sewing thread colors.  is machine type and compare the cost-benefitsperformers.additional higher use layout of putting Improve... theb olongestk times is required is called “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 Bottleneck process Time H a n e s 160 Work Allotment Time 140 140 140 120 105 115 100 80 80 60 40 20 0 A B C D E F G H Name of worker (In order of processes)... 0.365 32 Join shoulder 0.64 33 Top stitch shoulder 0.656 34 Attach collar 0.535 35 Close collar with size label 1.01 36 Sleeve attach 0.862 37 Top stitch armhole 0.678 38 Top stitch side seam 1.036 39 Attach & close cuff 0.696 40 Top stitch cuff 0.524 41 Hem bottom 0.947 Total SAM 22.322 Product: Full Sleeve Men’s Formal Shirt Brand: Arrow From given table draw a line diagram as well balance the line ... 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 0.42 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 11 Attach bias piece to cuff 0.874 12 Crease cuff 0.458 13 Hem cuff 0.501 14 R/s cuff 0.565 15 Trim cuff 0.36 16 Turn cuff 0.527 17 Crease cuff . ne Methods of eliminating bottlenecks from the line Line balancing in apparel manufacturing From Imbalanced line To Balanced line All in all… Sl. No. Operation List SAM 1 Pinning to profile 0.234 2. any point in the day. Why Line balancing @ the main job in line balancing is to eliminate or reduce wip (work in process) at bottleneck operations. @ keeps inventory costs low, resulting in higher. Line balancing © SOFT Student Handouts, By, Sunil Talekar, Faculty, SOFT-Pune What is line in apparel manufacturing? Line: an assembly line composed of several work