This report entitled “Comparison of Sewing Productivity among Different Sewing Floors” was prepared and submitted by Md. We have received endless support and guidance from many sources in the preparation of this report. First of all, I would like to thank my internship supervisor Kazi Rezwan Hossain, lecturer at Daffodil International University, for his continued guidance and assistance in the preparation of this report.
1st day when compare 2nd and 3rd floor, 2nd becomes high SMV and complex process so production and efficiency% is low. So, in this process, production and efficiency are high, but some factors proved that my concept was wrong. Through the capacity study, find out the bottleneck point, accept to large quantity of orders, division of work, proper layout, line balancing to help achieved production and efficiency.
4.1.1(Table) Sewing production & efficiency report 2nd floor 23 4.1.2 (Table) Sewing production & efficiency report 4th floor 24 4.1.3 1st day comparison between 2nd floor and 4th floor in Production and Efficiency 25 4.2.1 (Table )Sewing production and efficiency report 5th floor 26 4.2.2 (Table) Sewing production and efficiency report 3rd floor 27 4.2.3 2nd day comparison between 5th and 3rd floor in Production and Efficiency. 4.4.1 (Table) Sewing production and efficiency report 5th floor 31 4.4.2 (Table) Sewing production and efficiency report 4th floor 33 4.4.3 4th day comparison between 5th and 4th floor in Production and Efficiency Table) Sewing production and efficiency report 3rd floor 35 4.5.2 (Table) Sewing production and efficiency report 4th floor 36 4.5.3 5th day comparison between 5th and 4th floor in Production and Efficiency.
CHAPTER-1
Introduction
Introduction
Since the late 1970s, the RMG industry began to develop in Bangladesh primarily as an export-oriented industry, although the international market for RMG has grown rapidly due to the increase in personal non-recyclable income and change in lifestyle. The total indirect employment created by the RMG industry in Bangladesh is estimated to be around 250,000 workers. The total export earnings from textile and apparel was around USD 20.13 billion (during FY 2011-12), accounting for 78.60% input in the national export earnings.
To maintain competitiveness in global markets, traditionally major apparel suppliers/producers adopted an approach of relocating RMG factories to countries that were free of quota areas while still having sufficient trainable, low-priced labor. Labor productivity in Bangladesh's RMG sector is lower than that of many of its challengers. So day by day, RMG of Bangladesh is facing cut-throat cooperation and challenges in the global market.
Lean manufacturing is a system-wide policy that creates a culture in which everyone in the organization is constantly improving processes and production. The thesis is aimed at the application of various concepts of lean production, including the establishment of a cellular production system in the clothing industry.
Objective
One of the most important tools to be implemented is Cellular Manufacturing (Teamwork) approach which helps to build a variety of products with as little waste as possible.
CHAPTER-2
LITERATURE REVIEW
Garments Manufacturing
During the manufacture of clothing, a method flow diagram must be required to simply finish a nursing order associate. A method flow diagram also helps to know a garment producing technique that however measures the raw materials squarely, reborn in the wearable clothing.
Flow Chart of Garments Manufacturing Process / Technology
- Greding
- Marker making
- Cutting
- Process flow of Industrial Engineering
- Method Study
- Work Study
By following the technical sheet and artwork, pattern of each garment style should be made. Here, cutting parts need to be sorted out or bundled to easily send them into the next process. In order to minimize the damage of garments, all the garments must be drawn by maintaining buyers' instructions.
Industrial Engineering deals with the design, improvement and installation of an integrated system of people, materials and machinery for the benefit of mankind. The study of the method is a study that systematically examines all the details and criticisms in detail and thus helps to improve the work in a simple and beautiful way.
Importance/purpose of work study-
Motion study
Work study is the study by which minimal utilization of man, machine and materials is possible.
Classification of body movement-
- Time Study
- Line layout
- Capacity Study
- Procedure
- Cycle time
- SAM (Standard allowed minute)
- Allowance
- Balance
- Bottleneck
- Capacity Study
Timing is an analysis of whether all the components of a task are working properly to perform a specific task or under certain conditions. A layout works according to the standard that each unit is produced exactly the same and those operations are performed in an identified sequence. Work often flows from the back of the layout to the front and from the work station to the work station until the garment is finished.
Line layout is most efficient with long runs (high volume of identical products) when the sequence of processes and equipment does not need to be changed repeatedly. Depending on the volume needed, a plant may have a few lines that do the same style or several lines that each do different styles. If a style requires only one operator to sew the pockets and three operators to set pockets to keep the work in process flowing, then engineers will incorporate that into the layout.
Advantages of line layout can be less work in method than a skill center configuration and less handling between operations. Each operation depends on the previous one, and downtime, absenteeism and slow operators can interfere with the workflow. To counter these problems, some operators may need to be cross-trained to perform more than one operation, and replacement machines should be readily available for immediate replacement if equipment breaks down.
New trainees may be expected to meet production standards before being placed in a line position. Capacity study is a study where a complete picture or idea of how much work a machine operator can complete per hour is available. The amount of time required to complete a precise job or operation under an existing.
In the traditional line of performance measurement, the most important goals of evaluation are performance measurement, while the modern approach has focused on evaluated growth and performance enhancement. A modern evaluation system results in improved satisfaction, improved efficiency and, last but not least, improved efficiency of organizational activities. The restriction to the smooth flow of the operation restricts the flow of the level of production, productivity, efficiency is usually called a bottleneck.
Capacity/Hour
Some Important Formula Industrial Engineering
CHAPTER-3 METHODOLOGY
Methodology
P Meeting & Target Set up
- Procedure
The impact of the system of replacement (failures) of cut panels was analyzed by discussion and observation of personnel directly involved in the implementation process. A literature review was done by examining journals, books, articles, reports, blogs, websites, online newspapers and online journals. The production target should be determined here according to the customer's requirements; helps to meet the shipping date.
Machine layout is set here according to the total process required to complete a garment. To reduce the number of workstations, cycle time, line balancing is done, it is a very important process to achieve the production goal. Compare sewing productivity and efficiency between old 2nd floor, 3rd floor, 4th floor and 5th floor.
Chapter-4
RESULT AND DISCUSSION
4.1.3 1st day comparison between 3rd old and New 4th floor in Production and Efficiency
Production graph chart
Efficiency graph chart
Remarks
4.2.3 2nd day comparison between New 6th and Old 4th floor in Production and Efficiency
Production graph chart
Efficiency graph chart
4.3 3rd day Compare sewing productivity and efficiency between 2nd floor between before line balancing and after line balancing-.
4.3 3rd day Compare of sewing productivity and efficiency between 2nd floor between before line balancing and after line balancing-
Before line balancing & work sharing
After line balancing & work sharing
4.3.3 3rd day 2nd floor production and efficiency comparison between before and after line balancing & work sharing
Production graph chart
Efficiency graph chart
Day 4 Compare the sewing productivity and efficiency between the new floor 5 and 4-floor 5 and 4-.
4.4.3 4th day comparison between 5th and 4th floor in Production and Efficiency
Production graph chart
Efficiency graph chart
4.5 5th day Compare of sewing productivity and efficiency between 3rd floor and 4th floor-
4.5.3 5th day comparison between 3 rd floor and 4th floor in Production and Efficiency
Production graph chart
Efficiency graph chart
4.6 6th day Compare of sewing productivity and efficiency between 4th floor, 5th floor & 3rd floor-
4.6 6th day Compare sewing productivity and efficiency between 4th floor, 5th floor and 3rd floor.
4.6.4 6th day comparison between 4th floor, 5th floor & 3rd floor in Production and Efficiency
Production graph chart
Efficiency graph chart
Chapter-5 CONCLUSION
Limitation
The operator sometimes did not stay on the machine when we started to study our skills, study the time. The first time we collect data, the language of the operator does not match the language of the book. The requested information and data could not be found due to the busyness of the responsible persons.
Due to the busy schedule of the responsible persons, some necessary information and data were not available. This study could not be applied for further orders due to time constraints and lack of permission and assistance from the Director.
Conclusion
Future Scopes
