Line balancing in Garments Industry

[...]... that each definition has a corresponding percentage figure It is this figure that is used in leveling Production Calculation Target = (individual) 60 SMV Line Target = Actual Minutes Total M/C SMV Actual Minutes = No of M/C operators X working mints efficiency x present % Efficiency and Performance Calculations Efficiency = Earned Minutes (of individual) x 100 Available minutes Earned minutes = No... the operation Line Target TGT/Working Time = No of operator * working mints Total machine SMV Overall Efficiency = Earned SAH *100 Clock hours On std Efficiency = Earned SAH *100 Clock HRS – Lost HRS 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... manage WIP? (1) Production planning (2) Trims control (3) Production Build-up (4) Balancing (5) Cut Flow Control OUT PUT HIGH WIP LOW Balancing Matrix LOW 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... 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. .. 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 time 1.20.80.60.5... 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... be sold Demand? Uncertainty about the number of operators and performance Speculation? Total numbers Prediction? Attendance hours Uncertainty about work content Absenteeism Standard minute value Learning curve Measured Uncertainty about the equipment Estimated Performance Availability Reliability The pre Production plan for the next 13 week season has provided the following information Style Order... weekly load 1920000sm’s/13 weeks = 147692 SM’s in standard minutes If the factory employs 80 operators, has 4% absenteeism, works a 40 hour week, has a efficiency of 85%, what is the weekly capacity 80*40*0.96*0.85=156672sm’s in standard His the Factory sufficient capacity to meet the plan? I think its Yes minutes? Pitch Time Reference value for synchronization in the division of labor is called Pitch Time... minutes = No of produced pieces X SMV of that activity Available Minutes = Working Minutes Example 1 An operator worked for 8 hours on an activity of having a SMV of 5 She produced 82 pieces of that activity What was her efficiency? Efficiency = 82 x 5 x 100 = 85.42% 8 x 60 Example 2 An operator worked for 9 hours on activity of having SMV of 1.21 & 0.80 She produced 195 & 250 of those activities respectively... An operator worked for 8 hours on an activity of having a SMV of 5 She produced 82 pieces of that activity She had 40 minutes of stoppage time due to machine breakdown & power failure What was her performance? Performance = 82 * 5 * 100 ( 8 * 60) – 40 = 93.18% Allowance and Calculation Personal Needs and Fatigue = 7.5% Other (Standing) = 4.0% Machine Type Allowance % DNL SNL/BH DNC/50L SNC/30L BS/BT . 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. 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 by: Minhaz Ahmed Lecturer Department of Textile Engineering Introduction Line and work cell balancing is an effective tool to improve the throughput of assembly lines and work cells while reducing