First of all gratitude to Almighty Allah, by His kindness we can complete this thesis without any difficulty and without any problem. Mominur Rahman, Assistant Professor and Head (Head) of Textile Engineering Department of Daffodil International University for his motivation, continuous guidance, direction, valuable advice, constructive criticism, immense support and his continuous supervision help us to complete this thesis work. We would like to thank all faculty members and staff in our department for their support during this thesis.
In the apparel industry, production floor management is one of the most powerful techniques and one of the most challenging tasks to manage the floor in a proper way. Sewing floor or sewing department is one of the most important and critical stages in the garment industry. Facing this kind of problems, the production in that line is hindered and the sewing line cannot fulfill the production for one or two operations and this problem is known as bottleneck.
There are many ways to solve this problem and by reducing it the capacity or production will be increased. This thesis report will show how to reduce bottlenecks and its remarkable improvement in production.
Background of the Study
Objective of the study
Importance of the study
Scope of the study
Limitation of the study
Industrial Engineering is concerned with the design, development and improvement of 3M's integrated system for the benefit of mankind. Line balancing is the leveling of manpower or workload across the process on a line to remove process deadlock. Basically it minimizes or reduces worker idle time and increases worker productivity.
To remove the bottleneck in the process and balance the work flow or workload throughout the process and regulate the production rate. Precise machine settings help increase productivity and smooth workflow, and precise machine settings ensure the elimination of bottlenecks during production. SMV is mostly used in the apparel industry and is a time study process.
Basically, cycle time is the duration of time from the starting point of one task to the starting point of the next task. The capacity of the factory is how many machines they have also calculated the production. Bottlenecks occur due to the problems faced by the operators to complete the process at the right time.
Bottlenecking causes lower production, resulting in poor operator performance and less efficiency. Here we do capacity study and find out the bottleneck process and that is marking and attaching neck strap back is the first bottleneck process. After removing the bottleneck process through motion enhancement, one added extra manpower and changed the manpower from the LBR% we get.
After reducing the blocking process, we can reach the daily line target and improve the line balance. After removing the block by properly adjusting the workplace and improving the movement LBR% we get, LBR%= Bottleneck Process Manpower X SMV X 60. Here we select the basic blouse of different styles and different buyers from two factories to find out The bottleneck process.
Then this sewing line was chosen to increase the line balancing speed of the line and increase the line capacity to meet the daily target by removing the bottlenecks from that line. We collect the product SMV, take the cycle time of each worker, and then find out the capacity of each worker and find out the bottleneck process of that line. Implementing this increases the line balance and is around 88% and can easily meet the basic daily target.
We discovered a bottleneck process in a line which is the reason behind the lowest efficiency and lowest output or lowest production.
LITERATURE REVIEW
Definition of IE…
Responsibilities of Industrial Engineer
Objectives of Industrial Engineer
Organogram of IE Department
Definition of Line Balancing…
Base time: Base time is the time obtained by multiplying the rating factor by the cycle time. So, identifying the bottleneck operation and minimizing it is a very important task in the apparel sector. To figure out the hourly capacity, we need to take 5 cycle time and then average it and by dividing 3600 by the average cycle time, we can easily find out the capacity of a worker and we can easily find the bottleneck.
In this sewing line Bottleneck Mark and put neck tape on the back side which is done by Nazma and it is 23 number Process, Then make neck ring and servicing which is done by Shonali and it is 8 number process , Then Fasten breast pocket which is done by Shilpi and Salma. By implementing these things the line balance increased and it is around 57% and it can easily reach the daily line target. In this sewing line, Bottleneck Attach care label, which is made by Kader, and it is a 4-number process.
It was found that after solving this problem, the production is higher, the efficiency is higher, and it can easily reach the daily line target.
Objective of Line Balancing…
Importance of Line Balancing…
How to maintain Line Balancing…
Flow Chart of IE Department…
It can be defined as the time required to complete a task in a standard environment and in a standard manner. This rating is given to the worker based on his work performance and tells whether the worker's performance is good or bad. Work study is the study of industrial engineering, which plays an important role in reducing the cost of manufacturing garments and increasing productivity.
Method Study: Technique is a study of methodology that systematically collects and analyzes current and potential work processes in order to create and apply methods that are simpler and more efficient and minimize costs. Job Measurement: Job evaluation is the use of technique designed to determine the time for a newly skilled worker to complete a specified task at a given performance level.
Definition of Method Study…
To find out the reason behind this lowest capacity, we have to do production study and through this study we can easily find out in which section worker is facing problems or worker who is consuming more time. The bottleneck is the point in the production line where production slows down from the normal flow of production. Increase extra manpower: The first way to increase production at the bottleneck is to add more manpower.
By removing the obstacle the production will increase and it will be more production the company will benefit more and finally the company can play a role for the economic growth of a country and all the people of a country live in peace if their economic condition is good. If the bottleneck can be reduced, production will increase, the line will be balanced and have higher efficiency.
Objective of Method Study…
Steps involved in Method Study…
Definition of Time Study…
Tools used in Time Study…
For that reason, the line balance was 82% and did not meet the daily base target on that line. Where the label is placed, and then he can easily take the label and apply the label in a short time.
Flow chart of Time Study…
Definition of Cycle Time…
Definition of Capacity Study…
When a worker provides the lowest production capacity, the main job as an IE is to find out what is the problem behind the worker's lowest output or capacity. Method improvement: Industrial engineers calculate method study to find a better method to minimize bottleneck production in the sewing line. Develop layout plan: Putting highly skilled workers in the difficult operation and removing less skilled workers from the difficult operation is done by developing the workstation layout.
Solution: To solve the problem first of all, we modified Nazma from Mark and fixed the neck tape process and added the skilled operator Kanta. Then make neck ring and servicing which is done by Shonali and in this operation her movement is not right.
How to measure Capacity…
Definition of Production Study…
Necessity of Production Study…
Definition of Motion Study…
Basic Motion…
Benefits of Motion Study…
Definition of Bottleneck…
Arise of Bottleneck
Importance of Finding Bottleneck…
Ways of Reduce Bottleneck…
Materials and Method used in this Project…
Then we can reduce it by motion improvement, labor addition, employee exchange and organized workstation or workplace. Then we improve her movement and changed the machine and so her capacity has increased. When doing this research we are committed to being loyal to our research and we go out by completing this and we can simply make a difference by doing our research.
Data Collection
Bottleneck Operational Data…
- Techpack and Style Information…
- Product Description…
- Trims and Accessories Details…
- Construction Details…
- Measurement Sheet…
- Capacity Study During Bottleneck
- Capacity Study After Bottleneck Solving…
Bottleneck Operational Data…
- Sketch Details…
- Product Details…
- Color Details…
- Measurement Sheet…
- Capacity Study During Bottleneck…
- Capacity Study After Solving Bottleneck…
Solution: To solve this problem, we do a production survey and find that his workplace is not well organized, and since he took the label from the machine bed, it takes more time to adjust it. When it is researched, you have to remember that there are some ethical factors behind it. No one has a single health problem during this research because all the safety things are maintained here.
In our short period, we try our best to collect information for the completion of the dissertation, Due to some.
RESULT AND DISCUSSION
Bottleneck Result and Discussion… .............................................................................. 46-47
She does some unnecessary movements, as she often does, realignment and unnecessary shoulder movements. From production research, we also found that she is facing some problem such as thread breakage and needle breakage. This dissertation report shows what a bottleneck is, how the bottleneck can be measured and how it can be minimized. Such as unnecessary body or movement of the operator, problems during alignment, lack of skills, lack of proper organization of the workplace.
Codes and Standard Used…
Ethical Principle and Professional Commitment…
Impact on Society ,Health Safety and Legal Cultural Issues…
Benefits of Removing Bottleneck…
CONCLUSION…
