Yaa How To Ameliorate Productivity Together With Saving Terms Inwards Sewing Region

A STUDY ON IMPROVING PRODUCTIVITY AND SAVING COST IN THE SEWING DEPARTMENT
S.VIJAYAKUMAR,
M.TECH TEXTILE CHEMISTRY,
SSM COLLEGE OF ENGINEERING, KOMARAPLAYAM.
Email: vijaykpm.s@gmail.com
&
MR. P.MAHESWARAN 

M.TECH., ASSISTANT PROFESSOR,
DEPARTMENT OF TEXTILE CHEMISTRY,
SSM COLLEGE OF ENGINEERING,
KOMARAPALAYAM,NAMAKKAL-638183.

ABSTRACT
The projection has been undertaken at DINESH GARMENTS, TIRUPPUR. Which is engaged inward the manufacturing of garments for men’s together with women’s have on & kids garments. Apparel production, also known equally garment production is a physical care for where cloth is beingness converted into garments. The term apparel production is basically used when garments are manufactured inward a factory.

The projection is deals amongst improving the productivity together with saving the cost. Emphasizing on it steps has been taken to investigate together with eliminate non productive activities inward sewing subdivision inward monastic tell to salve fourth dimension together with cost together with lessen internal physical care for time. In this work, an approach to a to a greater extent than knowledge-based together with integrated physical care for planning together with command is presented. The outcome of this observation reflected that an manufacture may gain higher productivity together with profitability past times eliminating non productive activities. Influenza A virus subtype H5N1 full general overview over this evolution is given inward this project.

Keywords - Costs, Productivity, Profitability, Standard allowed infinitesimal (SAM).

CHAPTER-1

1.1 INTRODUCTION ABOUT TEXTILE AND APPAREL INDUSTRY:

The Indian textile industry has a important presence inward the economic scheme equally good equally inward the international textile economy. Its contribution to the Indian economic scheme is swell inward terms of its contribution to the industrial production, work generation together with unusual telephone commutation earnings. It contributes twenty percent of industrial production, ix percent of excise collections, together with eighteen percent of work inward the industrial sector, nearly twenty percent to the country’s total export earning together with four percent to the Gross Domestic Product.

India’s garment industry is characterized amongst fragmented construction having large number of units capable of producing little monastic tell sizes. However in that location are many units amongst substantial investments together with fully integrated.

The worldwide wearing clothing manufacture is 1 of the most of import sectors of the economic scheme amongst regard to investment, revenue, merchandise together with work generation all over the world. The wearing clothing manufacture inward Republic of Republic of India has substantially diversified on the ground of fashion, climate, region, civilization together with financial factors. Indian textile is witnessing swell growth together with evolution inward the industrial sector inward Republic of Republic of India equally good equally abroad. The significance of the wearing clothing manufacture is exclusively based on the contribution of the industrial productivity together with employment. Apparel sector inward totality contributes to the country's gross domestic product later agriculture. The of import segments covered inward wearing clothing manufacture include dwelling decor together with furnishings along amongst have on together with fashion accessories for kids, women together with men

1.2 INTRODUCTION TO THE PROJECT:

Generally inward an manufacture to a greater extent than focus is given on profit. Though in that location are dissimilar costs involved together with cost reduction internally spent past times an manufacture through reducing wastages, avoiding together with improving faulty operate would heighten profitability. Non productive activities designate that the client does non ponder equally adding value to his production (for example, relax,rest,waiting time, inspection time, zigzag crusade due to improper lay out, improper describe balancing, no proper planning, improper machine use, sharing of working instruments, absence of operators, workers’ fatigue etc. One of the ways to decrease wastages tin live elimination of non productive activities that tin termination inward drib inward time, cost, together with Pb time. As it is acknowledged from famous Russian saying Time is Money, if production fourth dimension is reduced the companionship tin capitalize less coin together with to a greater extent than savings.

1.3 COMPANY PROFILE:
Set upward inward 2007 inward a little way at Tirupur, the knitwear working capital missive of the alphabet of India, Dinesh Garments has made swell strides to travel a cite to reckon, amongst an annual turnover of 100crores.

The customers include Suncity- France, Next-UK Sergent major-US.

Mr. Dinesh, the founder-chairman of Dinesh Garments is a visionary amongst over 15years of sense inward knitwear. Dinesh Garments forcefulness lies inward greater transparency, timely delivery together with client service.

The Dinesh Garments has all departments that are required for an wearing clothing manufacture equally Knitting, Cutting, Printing, Sewing, labeling, Ironing & Packing.

1.4 OBJECTIVES OF THE PROJECT:

• To analyze the sewing physical care for through the application of Time Study method.
• To divulge production status of the describe together with the reasons for depression productivity inward sewing subdivision together with analysis the cost of the product.
• To implement the idea, so equally trim down the non-productivity inward sewing that volition termination inward improvement of productivity inward sewing subdivision together with saving the fourth dimension together with cost of organization.

1.5 NEED FOR THE STUDY:
Dinesh garments faces the problems of sewing describe efficiency together with its sewing describe productivity is less than industrial norm. The management of the companionship says that the target achieved past times sewing department was non satisfactory requires a through written report analysis of describe efficiency together with labour performance.

1.6 SCOPE OF THE STUDY

• The written report helps the scheme to improving productivity
• The written report helps the scheme saving the cost together with fourth dimension inward sewing department.

1.7 LIMITATIONS OF THE STUDY

• There are four dissimilar orders taken together with has been analyzed.
• Study has been conducted amongst the available grouping of workers together with all workers are non covered.

CHAPTER – 2
LITERATURE REVIEW

2.1 PRODUCTION:
Production is an organized activity of transforming raw materials into finished products. It is an intentional human activity of producing something useful. In production systems nosotros get got dissimilar resources equally input. The inputs are processed inward a serial of operations. The sequence, number, together with type of operations are specified for each input. The output of the scheme volition live consummate parts products etc. Production business office shows the human relationship betwixt the input together with the output of an organization. Study of production business office the maximum output which tin live achieved amongst given inputs, or say resources amongst a given province of engineering is determined.

The production business office tin live represented past times the simple mathematical equation which relates the outputs equally the business office of inputs , that is

Y = f (X1, X2, …., Xn)

Where Y = units of output, which is the business office of the quantity of 2 or to a greater extent than inputs

X1 = unit of measurement of labor, together with

X2 = unit of measurement of machinery, together with so on. Some quantities of production are assumed equally fixed, that is non varying amongst modify of output, together with such quantities never travel into inward the equation.

2.1.1 PRODUCTIVITY:
It is a really comprehensive concept, both inward its aim together with also inward its operational content. It is a affair of mutual cognition that higher productivity leads to a reduction inward cost of production, reduces the sales toll of an item, expands markets, together with enables the goods to compete effectively inward the ground market. It yields to a greater extent than payoff to the workers, shorter working hours together with greater leisure fourth dimension for the employees. In fact the forcefulness of a country, prosperity of its economy, measure of living of the people together with the wealth of the field are really largely determined past times the extent together with stair out of its production together with productivity. By enabling an increment inward the output of goods or services for existing resources, productivity decreases the cost of goods per unit, together with makes it possible to sell them at lower prices, so benefiting the consumers patch at the same fourth dimension leaving a margin for increment inward the payoff of the workers.

Productivity tin live defined inward many ways. Some of them are equally follows:

• Productivity is cipher but the reduction inward wastage of resources such equally labor, machines,materials, power, space, time, capital, etc. 

• Productivity tin also live defined equally human endeavor (effort) to create to a greater extent than together with to a greater extent than amongst less together with less inputs of resources so that the products tin live purchased past times a large number of people at affordable price. 

• Productivity implies evolution of an mental attitude of hear together with a constant urge to divulge better, cheaper, easier, quicker, together with safer agency of doing a job, manufacturing a production together with providing service. 

• Productivity aims at the maximum utilization of resources for yielding equally many goods together with services equally possible, of the kinds most wanted past times consumers at lowest possible cost. 

• Productivity processes to a greater extent than efficient plant involving less fatigue to workers due to improvements inward the layout of flora together with work, ameliorate working weather condition together with simplification of work. In a wider sense productivity may live taken to constitute the ratio of all available goods together with services to the potential resources of the group.

2.1.2 DIFFERENCE BETWEEN PRODUCTION AND PRODUCTIVITY:

As discussed earlier, production is an organized activity of transforming raw materials into finished products which get got higher value. Production of whatever commodity or service is the mass of output irrespective of the quantity of resources employed to accomplish the grade of output. Production inward an manufacture tin live increased past times employing to a greater extent than labor, installing to a greater extent than machinery, together with putting inward to a greater extent than materials, regardless of the cost of production.

But increment of production does non necessarily hateful increment inward productivity. Higher productivity results when nosotros pose inward production scheme an chemical factor of efficiency amongst which the resources are employed.

The combined input of a number of factors such equally land, materials, machines, capital, together with labor gives an output inward an industry. The ratio betwixt output together with 1 of these factors of input is normally known equally productivity of the factor considered. Productivity may also live considered equally a stair out of performance of the economic scheme equally a whole.

• Mathematically, Productivity = Output Value/Input Value
• Factor Productivity = Output due to the factor/ Input factor employed

2.1.3 WORKER EFFICIENCY:
A stair out of worker performance that compares measure fourth dimension allowed completing a task (lines)to the actual worker fourth dimension to consummate it.

To divulge out each operator's efficiency nosotros get got calculate.(Standard allowed minute) efficiency.

2.2 TIME STUDY:
The fourth dimension written report is considered to live 1 of the most widely used agency of work measurement. Basically, past times using fourth dimension study, an analysis volition live taking a little sample of a unmarried worker’s activity together with it to derive a measure for task of that nature.(Frederick Taylor)

Time written report is the physical care for used to determine the fourth dimension should get got good trained, qualified individual working at normal place, using a specific method to do a specific task.

To define fourth dimension written report merely about other way, it tin live said that fourth dimension written report is the systematic written report for the role of:

• Developing the preferred method together with scheme normally the most efficient.
• Standardizing this scheme together with method amongst all applicable employees.
• Provide the formats to educate all the applicable workers inward the preferred method.
• Then for purposes of quota together with or charge per unit of measurement setting, determining the fourth dimension required past times a good trained qualified person, working at normal place, using the preferred method to do a specific task or operation.

2.2.1 BENEFITS OF TIME STUDY:
Progressive companies do non desire to merely buy labour that would live measured only on the ground of time, such equally hourly workers. The way to buy labour is to buy output or useful work. Time written report is the cornerstone of the foundation of scientific management.

The benefits of properly executed fourth dimension studies are equally follow:

• Provides determination making information on how to lower unit of measurement costs at all levels of production.
• Shows how to teach greater output from a given amount of resources.
• Improves the scheduling of operate past times providing quotas.
• Accurate measure render the ground for farther planning of money, manpower, machines together with materials.
• Since fourth dimension written report signifies positive change, it continually focuses attending on cost of reduction together with control.
• Provides a meaningful ground for toll estimating.
• Offers workers a definite stated objective of what is expected of them inward a given stream past times stating what is expected from the average worker.
• Helps inward the solution of layout together with materials treatment problems past times giving accurate figures for planning human or machine utilization.
• Increases the marketplace together with or profits potential of the theatre past times helping to obtain lower unit of measurement costs
• Aids inward the training of budgets.
• Provides cumulative guidelines for management to either come across or plough over standards of performance laid for their bridge of control.
• Places greater emphasis on character past times allowing payment to workers on only the output that meets the recorded standards.
• By showing what is expected from the “average” worker, it allows private to compare them to this average together with laid their ain operate pace. By allowing workers to do this they play large parts inward determining their ain get got dwelling pay.

2.2.2 SCOPE OF TIME STUDY:
Time written report used for goal setting, charge per unit of measurement setting together with costing. Operational analysis or methods study is used for methods improvement.

Manual operate is performed the job is finding the most economical way to perform tasks .the interrogation ofttimes asked is, how much operate should live done inward a given amount of time? Time written report tin that question. For the role of clarity when reference is made to fourth dimension written report it is meant to include the prior together with necessary motility study.

2.2.3 STEPS TO PERFORM TIME STUDY:

To perform a proficient Time Study, starting fourth dimension of all, physical care for has to live equally follows

• Observe the functioning
• Find out if the operator are using the right operate method
• Ask the supervisor to explicate our role to the operator
• Adjust the operate method inward instance of divergence
• Observe the functioning breakdown the operations into elements
• Once ready prepare the fourth dimension operate written report canvas
• Evaluate the rating factor of each chemical factor
• Register the rating factor nether the column of each chemical factor
• Take the readings per chemical factor
• Calculate the written report

2.2.4 TIME STUDY EQUIPMENT REQUIREMENTS:

The success of fourth dimension written report is to a greater extent than affected past times the abilities of the fourth dimension written report individual than past times the technique or tool used .proper fourth dimension written report equipment is simple together with few pieces are required. The basic fourth dimension written report toolkit contains:

• Stop scout
• Time written report forms
• Ball dot pen or difficult pencil
• Calculator.

The higher upward includes only the bare essentials. Influenza A virus subtype H5N1 Only scout decimal infinitesimal snap dorsum timer together with the simplest of cast volition yield a termination equally multi-or-electronic watches inward the hands of a competent practitioner. Big expensive fourth dimension written report equipment volition non aid improve methods, bargain amongst people correctly, charge per unit of measurement performance or improve our judgment.

2.2.5 TIME AND METHOD STUDY:

There are 2 principal systems of primary operate measuring inward use. One depends upon the mightiness of a trained Work Study practitioner to create upward one's hear what is the charge per unit of measurement of working equally good equally fourth dimension taken. This is known equally Time Study. The other relies upon the methods used, on the agreement that, for a given method, in that location is only 1 measure time. The basic data, which refer to the movements which travel to brand upward the method, were derived from extensive together with controlled fourth dimension studies. This is known equally Pre-determined Motion Time Study or “PMTS”. (Benjamin W. Niebel)

2.2.6 STANDARD MINUTE VALUE (SMV)OR STANDARD ALLOWED MINUTE (SAM):

Industrial engineering, the measure fourth dimension is the fourth dimension required past times an average skilled operator, working at a normal pace, to perform a specified task using a fourth dimension written report method. It includes appropriate allowances to allow the individual to recover from fatigue and, where necessary, an additional allowance to encompass contingent elements which may travel on but get got non been observed.

2.2.7 ALLOWANCES:
When a measure fourth dimension is calculated non only the basic times but the allowances are used. Although they are built into the fourth dimension for a unmarried garment it is assumed that they stand upward for activities which may get got upward to one-half an hr or so but which travel on at intervals during the working day. It agency that the number of garments produced during a written report volition live greater than that indicated past times the measure infinitesimal value would suggest, since in that location volition likely live few breaks during the recorded time.

Allowances are applied to compensate on the unloose energy consumed past times the employee together with to facilitate calculations. This category varies from 1 mill to merely about other depends on the environmental grade together with working minutes per day. Each mill should re-evaluate the pct of the PFD together with attempt to trim down equally much equally possible.

2.2.8 PERSONAL AND FATIGUE:
No 1 plant difficult all day. There are occasions when most people similar to teach upward from their machines together with get got a break. You can’t expression operatives to travel for long periods without going to the lavatory. The amount of fourth dimension devoted to non-productivity activity volition vary from individual to person, equally volition the charge per unit of measurement of which they work. This personal together with fatigue allowance caters for both together with ensures that proper incentives are combined amongst merely about liberty of action. This allowance is applied that proper incentives are combined amongst merely about liberty of action. This allowance is applied to all production operations but may live greater for heavy operate than for light.

CHAPTER - three
METHODOLOGY

3.1 INTRODUCTION:

Influenza A virus subtype H5N1 fourth dimension written report of garment sewing elemental functioning was conducted inward production physical care for of the Dinesh garment. The written report is carried for the children garment have on produced past times the company.

Based on the observed fourth dimension for each chemical factor of sewing, Average Basic Time, Standard Allowable Minute for each functioning is calculated equally detailed inward the next sections.

Subsequently the analysis of residuum of operate content amid the workers of the Sewing Group is carried out so equally to divulge the reach for improvement inward productivity.

3.2 TYPE OF RESEARCH:
The type of enquiry adopted is descriptive enquiry quantitative inward nature. Descriptive enquiry is aimed to depict information together with characteristics most the population or phenomenon beingness studied. Here the enquiry measures the fourth dimension for performing diverse elemental operations involved inward sewing garments so equally to divulge the argue for depression productivity.

3.3 DATA COLLECTION:
Data collection is a decisive stair inward the enquiry process. The starting fourth dimension manus information needed for this written report was obtained through TIME Study of chemical factor of operations involved inward sewing of garments. The timings are observed for the normal methods of functioning carried out for each chemical factor of Sewing. The measure physical care for followed for a Time Study using suitable halt scout is adopted for the study.

3.4 PRIMARY DATA SOURCE:
The primary information sources are

• Observation of fourth dimension inward the execution of an chemical factor of a sewing physical care for

3.5 SAMPLE SIZE:
Based on the past times sense & practise of the companionship sampling size simple functioning is chosen. For the each chemical factor involved inward the sewing of casual shirt of wills life social club 10 readings were taken for Time of performing the operation.

3.6 CALCULATION OF SAM THROUGH TIME STUDY:

Step 1: Select 1 functioning for which y'all desire to calculate SAM.

Step 2: Take halt watch. Stand past times side of the operator. Capture wheel fourth dimension for that operation. (cycle fourth dimension – total fourth dimension taken to do all plant needed to consummate 1 operation, i.e. fourth dimension from selection upward part of starting fourth dimension slice to side past times side selection upward of the side past times side piece). Do fourth dimension written report for consecutive 5 cycles. Discard if flora abnormal or non value added fourth dimension inward whatever cycle. Calculate average of the 5 cycles. From fourth dimension written report is called wheel time. Convert this wheel fourth dimension into basic fourth dimension past times multiplying wheel fourth dimension amongst operator performance rating.

Basic Time = Cycle Time X performance Rating

Step 3: Performance rating. Now y'all get got to charge per unit of measurement the operator at what performance grade he was doing the task seeing his crusade together with operate speed.

Step 4: Standard allowed minutes (SAM) = (Basic infinitesimal + Bundle allowances + machine together with personal allowances). Add package allowances (10%) together with machine together with personal allowances (20%) to basic time. Similarly, for all the functioning related to the higher upward garments way measure allowed infinitesimal or SAM was calculated. The calculate SAM both for excluding together with including non productive time. Productive together with non productive activities inward each steps wherever flora was identified for the higher upward physical care for for each way together with the SMV or SAM inward minutes were noted. Finally the ultimate SMV variation was calculated.

3.7 PRODUCTION CALCULATION:
The production solar daytime is calculated using the derived SAM together with total working hours per solar daytime of the companionship equally given below

                                    Total production fourth dimension
Production per solar daytime =………………………….. X Efficiency
                                             SAM

Total production fourth dimension = No. of operator X Time

The higher upward formula is used for calculation inward the project.

3.8 GARMENT COSTING:
Calculated equally follows

1. Production / solar daytime ……………………
2. Production/ month…………………..
3. Production / year……………………
4. Cost/garment………………………..
5. Total cost =No of physical care for X cost/ garment

3.9 ELEMENTS OF OPERATIONS INVOLVED IN THE SEWING PROCESS OF BASIC LEGGING AS FOLLOW:

Front ascent attached
↓
Back ascent attached
↓
Lace ironing
↓
Lace attached
↓
Lace finishing
↓
Elastic label attached inward waist band
↓
Inside finishing
↓
Care label attached
↓
Hemming on waist band
↓
Peak on crotch together with bottom of legging

CHAPTER – four
ANALYSIS AND INTERPRETATION

4.1 ESTIMATION OF STANDARD ALLOWED MINUTE (SAM) IN INCLUDE/EXCLUDE NON PRODUCTIVITY (NP) ACTIVITIES:

SAMPLE-1

S.No	Operation	Sam include NP activities	Sam exclude NP activities	Number of Operator	m/c
1	Front ascent attached	0.2366	0.2093	2	O/L
2	Back ascent attached	0.2002	0.1820	2	O/L
3	Lace ironing	0.0910	0.0780	1	-
4	Lace attached	0.0780	0.0650	1	F/L
5	Lace finishing	0.0650	0.0520	1	F/L
6	Elastic label attached	0.2275	0.2002	1	F/L
7	Elastic label finished	0.1170	0.0910	1	O/L
8	Inside finishing	0.2730	0.2356	2	O/L
9	Care label attached	0.0910	0.0780	1	F/L
10	Hemming to waist band	0.1365	0.1092	1	F/L
11	Peak on bottom of legging	0.1638	0.1274	2	O/L
	TOTAL	2.4796	2.2277	15

Table-4.1 Data collection sample-1

SAMPLE-2

S.No	Operation	Sam include NP activities	Sam exclude NP activities	Number of Operator	m/c
1	Front ascent attached	0.2466	0.2293	2	O/L
2	Back ascent attached	0.2202	0.1920	2	O/L
3	Lace ironing	0.0910	0.0780	1	-
4	Lace attached	0.0780	0.0750	1	F/L
5	Lace finishing	0.0760	0.0620	1	F/L
6	Elastic label attached	0.2175	0.2002	1	F/L
7	Elastic label finished	0.1270	0.1000	1	O/L
8	Inside finishing	0.2730	0.2456	2	O/L
9	Care label attached	0.0810	0.0780	1	F/L
10	Hemming to waist band	0.1265	0.1192	1	F/L
11	Peak on bottom of legging	0.1638	0.1574	2	O/L
	TOTAL	2.5006	2.3367	15

Table-4.1.1 Data collection sample-2

SAMPLE-3

S.No	Operation	Sam include NP activities	Sam exclude NP activities	Number of Operator	m/c
1	Front ascent attached	0.2366	0.2193	2	O/L
2	Back ascent attached	0.2102	0.1920	2	O/L
3	Lace ironing	0.0910	0.0880	1	-
4	Lace attached	0.0780	0.0750	1	F/L
5	Lace finishing	0.0650	0.0520	1	F/L
6	Elastic label attached	0.2275	0.2102	1	F/L
7	Elastic label finished	0.1170	0.0910	1	O/L
8	Inside finishing	0.2730	0.2556	2	O/L
9	Care label attached	0.0910	0.0880	1	F/L
10	Hemming to waist band	0.1365	0.1192	1	F/L
11	Peak on bottom of legging	0.1638	0.1474	2	O/L
	TOTAL	2.4896	2.3377	15

Table-4.1.2 Data collection sample-3

SAMPLE-4

S.No	Operation	Sam include NP activities	Sam exclude NP activities	Number of Operator	m/c
1	Front ascent attached	0.2566	0.2493	2	O/L
2	Back ascent attached	0.2202	0.1920	2	O/L
3	Lace ironing	0.1010	0.0980	1	-
4	Lace attached	0.0980	0.0950	1	F/L
5	Lace finishing	0.0750	0.0720	1	F/L
6	Elastic label attached	0.2175	0.2102	1	F/L
7	Elastic label finished	0.1570	0.1410	1	O/L
8	Inside finishing	0.2830	0.2756	2	O/L
9	Care label attached	0.0910	0.0880	1	F/L
10	Hemming to waist band	0.1565	0.1492	1	F/L
11	Peak on bottom of legging	0.1738	0.1674	2	O/L
	TOTAL	3.0296	2.5377	15

Table-4.1.3 Data collection sample-4

SAMPLE-5

S.No	Operation	Sam include NP activities	Sam exclude NP activities	Number of Operator	m/c
1	Front ascent attached	0.2366	0.2293	2	O/L
2	Back ascent attached	0.2202	0.1920	2	O/L
3	Lace ironing	0.1010	0.0980	1	-
4	Lace attached	0.0980	0.0850	1	F/L
5	Lace finishing	0.0750	0.0680	1	F/L
6	Elastic label attached	0.2175	0.2002	1	F/L
7	Elastic label finished	0.1570	0.1410	1	O/L
8	Inside finishing	0.2830	0.2656	2	O/L
9	Care label attached	0.0910	0.0880	1	F/L
10	Hemming to waist band	0.1565	0.1392	1	F/L
11	Peak on bottom of legging	0.1738	0.1574	2	O/L
	TOTAL	3.0096	2.4637	15

Table-4.1.5 Data collection sample-5

4.2 PRODUCTION ANALYSIS USING OBSERVED SAM VALUES INCLUDING NON-PRODUCTIVITY TIME:

Table-4.2 Production analysis using observed SAM values including NP time

Chart-4.2 Production analysis using observed SAM values including NP fourth dimension

OBSERVATION:
The higher upward observed SAM value include non productivity results say that for average 2.68 SAM together with corresponding production per hr for employee working at 60%,70%,80% & 90% efficiency volition live 201,235,269,302 respectively.

4.2.1 PRODUCTION ANALYSIS USING OBSERVED SAM VALUES EXCLUDING NON-PRODUCTIVITY TIME:

Table-4.2.1 Production analysis using observed SAM values excluding NP fourth dimension

Chart-4.2.1 Production analysis using observed SAM values excluding NP fourth dimension

OBSERVATION:
The higher upward observed SAM value include non productivity results say that for average 2.37 SAM together with corresponding production per hr for employee working at 60%,70%,80% & 90% efficiency volition live 227,266,303,341 respectively.

4.2.2 PRODUCTION ANALYSIS VARIABLE CHART:

Table-4.2.2 Production analysis

Chart- 4.2.2 Production analysis

OBSERVATION:
The higher upward production analysis variable termination say that for an efficiency of 60, 70, eighty & ninety the production variation betwixt include together with exclude NP output/hrs volition live 26, 31, 34 together with 39 respectively.

4.2.3 FINANCIAL CALCULATION:
In Dinesh garments average CMT cost for the higher upward experimental way is considered equally RS60 per piece.

Table- 4.2.3 financial calculation

Chart- 4.2.3 financial calculation

OBSERVATION;
The higher upward financial results say that production variation inward output/hrs 26, 31, 34 & 39 causing loss of most 4867000, 5803200, 6364800 & 7300800 per yr respectively.

CHAPTER – 5
FINDINGS, SUGGESTIONS AND CONCLUSIONS

FINDINGS

5.1 REVISED ESTIMATION OF STANDARD ALLOWED MINUTE (SAM) IN INCLUDE/EXCLUDE NON PRODUCTIVITY (NP) ACTIVITIES:

SAMPLE-1

S.No	Operation	Sam include NP activities	Sam exclude NP activities	Number of Operator	m/c
1	Front ascent attached	0.2166	0.2093	2	O/L
2	Back ascent attached	0.2002	0.1720	2	O/L
3	Lace ironing	0.0810	0.0780	1	-
4	Lace attached	0.0680	0.0650	1	F/L
5	Lace finishing	0.0650	0.0520	1	F/L
6	Elastic label attached	0.2175	0.2002	1	F/L
7	Elastic label finished	0.1070	0.0810	1	O/L
8	Inside finishing	0.2530	0.2356	2	O/L
9	Care label attached	0.0810	0.0780	1	F/L
10	Hemming to waist band	0.1265	0.1092	1	F/L
11	Peak on bottom of legging	0.1438	0.1274	2	O/L
	TOTAL	2.3596	2.2074	15

Table-5.1 Revised Data collection sample-1

SAMPLE-2

S.No	Operation	Sam include NP activities	Sam exclude NP activities	Number of Operator	m/c
1	Front ascent attached	0.2466	0.2393	2	O/L
2	Back ascent attached	0.2102	0.1920	2	O/L
3	Lace ironing	0.0810	0.0780	1	-
4	Lace attached	0.0780	0.0750	1	F/L
5	Lace finishing	0.0760	0.0620	1	F/L
6	Elastic label attached	0.2175	0.2002	1	F/L
7	Elastic label finished	0.1170	0.1000	1	O/L
8	Inside finishing	0.2530	0.2456	2	O/L
9	Care label attached	0.0810	0.0780	1	F/L
10	Hemming to waist band	0.1265	0.1192	1	F/L
11	Peak on bottom of legging	0.1608	0.1574	2	O/L
	TOTAL	2.4476	2.3467	15

Table-5.1.1 Revised Data collection sample-2

SAMPLE-3

S.No	Operation	Sam include NP activities	Sam exclude NP activities	Number of Operator	m/c
1	Front ascent attached	0.2266	0.2193	2	O/L
2	Back ascent attached	0.2102	0.2020	2	O/L
3	Lace ironing	0.0910	0.0880	1	-
4	Lace attached	0.0780	0.0750	1	F/L
5	Lace finishing	0.0650	0.0620	1	F/L
6	Elastic label attached	0.2275	0.2102	1	F/L
7	Elastic label finished	0.1170	0.0910	1	O/L
8	Inside finishing	0.2630	0.2556	2	O/L
9	Care label attached	0.0910	0.0880	1	F/L
10	Hemming to waist band	0.1365	0.1192	1	F/L
11	Peak on bottom of legging	0.1638	0.1474	2	O/L
	TOTAL	2.4696	2.3577	15

Table-5.1.2 Revised Data collection sample-3

SAMPLE-4

S.No	Operation	Sam include NP activities	Sam exclude NP activities	Number of Operator	m/c
1	Front ascent attached	0.2466	0.2493	2	O/L
2	Back ascent attached	0.2002	0.1920	2	O/L
3	Lace ironing	0.1010	0.0980	1	-
4	Lace attached	0.0980	0.0950	1	F/L
5	Lace finishing	0.0750	0.0720	1	F/L
6	Elastic label attached	0.2175	0.2102	1	F/L
7	Elastic label finished	0.1570	0.1410	1	O/L
8	Inside finishing	0.2830	0.2756	2	O/L
9	Care label attached	0.0910	0.0880	1	F/L
10	Hemming to waist band	0.1565	0.1492	1	F/L
11	Peak on bottom of legging	0.1738	0.1674	2	O/L
	TOTAL	2.5996	2.5377	15

Table-5.1.3 Revised Data collection sample-4

SAMPLE-5

S.No	Operation	Sam include NP activities	Sam exclude NP activities	Number of Operator	m/c
1	Front ascent attached	0.2366	0.2293	2	O/L
2	Back ascent attached	0.2002	0.1920	2	O/L
3	Lace ironing	0.1000	0.0980	1	-
4	Lace attached	0.0880	0.0850	1	F/L
5	Lace finishing	0.0750	0.0680	1	F/L
6	Elastic label attached	0.2175	0.2002	1	F/L
7	Elastic label finished	0.1470	0.1410	1	O/L
8	Inside finishing	0.2730	0.2656	2	O/L
9	Care label attached	0.0910	0.0880	1	F/L
10	Hemming to waist band	0.1565	0.1392	1	F/L
11	Peak on bottom of legging	0.1738	0.1574	2	O/L
	TOTAL	2.5586	2.4637	15

Table-5.1.5 Revised Data collection sample-5

5.2 REVISED PRODUCTION ANALYSIS USING OBSERVED SAM VALUES INCLUDING NON-PRODUCTIVITY TIME:

Table- 5.2 revised production analysis using observed SAM values including NP time

Chart -5.2 revised production analysis using observed SAM values including NP fourth dimension

OBSERVATION:
The higher upward revised observed SAM value include non productivity results say that for average 2.48 SAM together with corresponding production per hr for employee working at 60%,70%,80% & 90% efficiency volition live 218,253,289,326 respectively.

5.2.1 REVISED PRODUCTION ANALYSIS USING OBSERVED SAM VALUES EXCLUDING NON-PRODUCTIVITY TIME:

Table -5.2.1 revised production analysis using observed SAM values including NP fourth dimension

Chart -5.2.1 revised production analysis using observed SAM values including NP time

OBSERVATION:
The higher upward revised observed SAM value exclude non productivity results say that for average 2.37 SAM together with corresponding production per hr for employee working at 60%,70%,80% & 90% efficiency volition live 227,265,303,341 respectively.

5.2.2 REVISED PRODUCTION ANALYSIS VARIABLE CHART:

Table- 5.2.2 revised production analysis

Chart- 5.2.2 revised production analysis

OBSERVATION:
The higher upward revised production analysis variable termination say that for an efficiency of 60, 70, eighty & ninety the production variation betwixt include together with exclude NP output/hrs volition live 9, 12, xiv together with fifteen respectively.

5.2.3 REVISED FINANCIAL CALCULATION:

In M.S.Kaarthikeyan garments average CM cost for the higher upward experimental way is considered equally RS60 per slice

Table- 5.2.3 Revised financial calculation

Chart- 5.2.3 revised financial calculation

OBSERVATION
The higher upward financial results say that production variation inward output/hrs 9, 12, xiv & fifteen causing loss of most 1684800, 2246400, 2620800 & 280800 per yr respectively.

COST INFERENCE:
It has been observed from the cost calculation per saving through fourth dimension written report is equally follows

Table -5.2.4 Cost Saving Calculation

5.3 SUGGESTIONS:
Some of the suggestions provided to trim down non-productive activities fourth dimension are proper production planning, effective application of industrial engineering, good trained operator, proper layout plan, minimum rework, smoothen running of sewing machine, proper describe balancing, right fourth dimension oiling to the sewing machineries, ensuring character production, sufficient numbers of working aids tin live provided for smoothen working, stickers tin live used for identification, right shade variation, length, width of the cloth should live issued past times proper identification, proper allotment of manpower is necessary, books to greenback downwards production to live given equally 1 mutual mass is used, proper character checking, minimum waiting time, inspection time, reduced zigzag crusade etc. These recommendations were suggested to the sewing department.

5.4 CONCLUSION:
The suggestive tools developed inward this projection encompass a comprehensive serial of aspects inward minimizing cost together with fourth dimension inward the sewing subdivision of wearing clothing industries past times ensuring character production. It was observed that fourth dimension was saved together with cost related to fourth dimension was utilized properly (reduced past times eliminating non productive activities). The written report clearly indicates that past times eliminating non productive activities inward the sewing subdivision fourth dimension equally good equally cost are saved which get got an of import impact on overall mill economy.

Bibliography:

1. Feld,M.W.,(2000).Lean Manufacturing: Tools, Techniques, together with how to usage them. Boca Raton, London: The St. Lucie Press
2. Kumar, S. A. (2008). Production together with Operations Management. Daryaganj, Delhi, India: New Age International, p. 217-220.
3. (viyellatex group)(n.d.). Retrieved december 2012, from viyellatex group: http//www.viyellatexgroup.com
4. Shahidul, M. I. together with Syed Shazali, S. T. Dynamics of manufacturing Productivity: Journal of Manufacturing Technology Management Vol. 22 No. 5, 2011, p. 664-678
5. (Opex Group) (n.d.). Retrieved december 2012, from Opex group: http//www.opexgroup.com

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