Monday, February 1, 2016

Some Important Tools in Industrial Engineering at Garments Industry & Simplify & Clarify These Tools with Short Definition. Part- iv



Capacity Study: In a Garment Industry operator’s capacity means the total minutes or hours or in pieces he/she produces per day. The method used to calculate the operator’s productions capacity is called Capacity Study.
Thus
The Supervision of the arrangement recording, and mixing of a record the overall sound quality or character of a recording is called Capacity Study.
Idle Time: During the course of production, it is observed that operators are idle and wait for production build up to make them go into motion, this idle time is loss of time and production.
Production: The processes and methods used to transform tangible inputs (raw materials, semi-finished goods, sub-assemblies) and intangible inputs (ideas, information, knowledge) into goods or services, resources are used in this process to create an output that is suitable for use or has exchange value.
Operational Breakdown/Bulletin: An Operational Breakdown or Bulletin is one of the initiate tools for an Industrial Engineer. An operational bulletin helps to set a sewing production line, with correct number of machines, manpower’s and other necessary tools.
Breakdown is a listing of the content of a job by elements. A garment has some parts and some group of operation to making it. Breakdown means to writing down all parts & all process/operation after one another lying with the complete garment according to process sequences. Both manual and machine operations are include in the list. It is must to write down the estimated SMV, type of machine & attachments beside each & every process.

Sewing Line Layout:
The Sewing Line layout can be defined as the way sewing workstations are placed in the sewing floor to form a line (or batch) that works on single style.
Line Balancing: Line balancing means allocation of machines or works to individual work. According to the working sheet the step wise setting of machine and work and individualization of the whole worker into some necessary parts to the worker is called line balancing.

Operator’s rating: The rating is The Assessment of The Worker of Working Relationships to the Observer Concept of The Rate Resembling to Standard Label.  Rating Is a Subjective Comparison of Any Condition or Activity to a Benchmark, Based Upon Observer Experience. When the Observer Record an Operator Skill Test, Applying a rating will define the Operator’s Performance or Skills. The Rating is a Strategy Accustomed to Measure the Motion Speed and Effectiveness of An Operator Acting an Activity or Group of Some Activities.
Rating Scale:
British Standard Rating Scale:
          0        = No Activity.
          1-50    = Very Slow, Clumsy, Operator Becomes Tired or Seems To Be Half Sleep, Inapt Movement, Feeble, Careless For Doing The Job.
          51-75  = Operator Trying to Produce Production But Their Motion Problem, Negligence About Production, Unconscious About working Environment, They Cannot Meet The Right Quality And Quantity Too.
           76-100 = Very High Skilled and Standard Speed of Motion, Faster Than the Others. They are trying to provide their 100% Concentration about The Task They Should Take.
Factors Affecting the Rating:
          The Study Person Should Be Careful Not To Rate Too Hight When=>
          The Worker is Looking Worried and Hurried.
          The Worker is Obviously Being Over careful
          The Jobs Seems To Be Difficult To Study Person
          The Study Person is Working Very Fast.
100% Performance Rating or Normal Performance or Standard Performance:
For Attaining 100% Performance Rating or Normal Performance or Standard Performance, it Need to Fulfill Some Essential Conditions.
          Operators Must Be Qualified.
          Operators Must Have to Enough Exertion Within Working Day Period.
          Operators Must Have to Maintain The Sewing Conditions Of The Specific Orders Or Styles.
          Operators Must Have To Follow The All Compliance Rules and Regulations.
          Operators Must Have To Fluid Motions Without Hesitation.
          No False Beginning or Any Kinds of Rework or Duplications.
          Operator must be Compatible, Coordinated, effective rhythm.
          Operator must Conscious about Wastage in Action or Work, Punctual about Times.
          Intentness Centered on the Task.
For Collecting The Accurate Rating Observers Need To Follow The Some Essential Contents.
          Have Knowledge Garments Layout, Individual Sewing Processes, Specific Operations, Method to Calculate the Rating, Operation SMV, and what is The Standard Operating Procedures for the Specific Operation or Task.
          Need a Very Good Eye For Observing The Operator Motions.
          Find out The Original Ineffective Time (such as: Fumbles, Hesitations, Unconsciousness, Inattentive and Other Lost Motions These are Impact for Decreasing the Productions)   by Using Very Intensive Monitoring or Observation.
          Avoid The Unwitting Occurrence Whose Are Out of Operators Control.
          Being Honest and Avoid Partiality, Corruptions, and Emotions When Observing Fast And Slow Operators In Succession.
          For Getting Better Accuracy, Observers Must Have To Increase The Number of Cycles Observing Time.
Some Effective Applications of Operators Rating In Garments Industry:
The rating is used in Garment Industry in Various purposes. Among These:
          Operators Motivation: An Operator Produce Per Hour 120 Pieces of Garments. But The Observer Knows That She/he Has The Capacity For Doing 150 Pieces of Garments. That Situation Observer Increase His/hers Rating Performance to Motivating His/hers For Increase the Productions.
          Calculating The Basic Time Or Standard Time: Suppose An Operator Doing An Operation Using Too Much Time. But The Observer Knows That This is Not the Basic or Standard Time for Doing This Operation, That Time Observer Gives This Operator Low Rating or below 100%. We Know That,
Basic Time = (Observing or Cycle Time × Performance Rating)     
Say One Operator Taking .3 Min For Doing On Operation. So Cycle Time is .3, and the Observer Gave His/hers 80% Performance Rating.
Than The Basic Time = (.30 × 80%) Min
                 = (.30 ×.80) Min                          
                 = .24 Min
On The Other Hand An Operator Doing The Same Operation Using 0.16 Min. That’s Meant This Operator Motion Speed Too Much Fast. When We Calculate The Basic Time We Give Him The Performance Rating Above 100%. Suppose That the Performance Rating is 150%
Than The
Basic Time = (.16  150%) Min
         = (.16 1.5) Min                          
         = .24 Min
          When Observer Taking Operator Skill Test, There Also Need to Measure Operator Performance Rating For Grading The Operator. Let An Operator Take 30 Sec. For Completing an Operation and Observer Gives His/hers 70% Performance Rating. That Means Operator is Low Efficient. For This Operator When Calculating The Production Capacity We Find:
We Know That,
Basic Time = (Cycle Time × Performance Rating) Sec.
                       = (30 × 70%) Sec.
                       = 21 Sec.
As a Result We Find Low Efficient Operator’s Capacity Time is getting less and For This His/hers Production Capacity Is Getting Higher.
On The Other Hand Let An Operator Take 15 Sec. For Completing an Operation and Observer Gives His/hers 125% Performance Rating. That Means Operator is Very High Efficient. So This Operator Production Capacity Goes To:
Basic Time = (Cycle Time  Performance Rating) Sec.
                       = (16  125%) Sec.
                       = 20 Sec.
And In This Term We Find Higher Efficient Operator’s Capacity Time getting high and As a Result His/hers Production Capacity is Getting Lower.
Ultimately This Make An Illusion.
For This I Make a Formula Which May Solve All This Doubt.
Let an Operator’s Cycle Time of an Operation is 30 Sec. Observer Gives His/hers 70% Performance Rating. So-
Time Capacity = {Cycle Time + Cycle Time  (100% Performance Rating - Given Performance Rating}
                                  = 30 + 30 (100% - 80%) Sec.
                                  = 30 + (30  20%) Sec.
                                  = (30 + 6) Sec.
                                  = 36 Sec.

And Other Side Let an Operator’s Cycle Time 20 Sec. Given Performance rating 125%, so-
Time Capacity = {Cycle Time + Cycle Time  (100% Performance Rating - Given Performance Rating}
                                  = 20 + 20 (100% - 125%) Sec.
                                  = 20 + {20  (-20%)} Sec.
                                  = (20 - 4) Sec.
                                  = 16 Sec.
We Know If the Cycle Time is increasing than the Production Is Going Down. And If The Cycle Time Is Decreasing Than The Production Is Going UP. Therefore Cycle Time is Inverse to Production.
Again If an Operator’s Performance Rating is Higher, So That She/he Produces More Production than the Observer Expectation. Hence the Performance Rating Is Proportional To Production.
So the First Equation Is
Production 1/ (Operator’s Cycle Time) …………………………….   (i)
Again

Production Operator Performance Rating……………  (ii)

Comparing Equation (i) and (ii) We Can Say,

Operator's Performance Rating 1/ (Operator’s Cycle Time)

Therefore, if the Performance Rating Is Increasing, The Cycle time is Going Down and if the Performance Rating Is Decreasing the Cycle Time Is Going UP.

Basically Operator Performance Rating Measurement Totally Dependent on Observer’s Experience or Discretion.
If Observer Thought That Operator’s Cycle Time What She/he Get From The Observation Period Is Not The Same When She/he Doing This In The Production Environment. Either The Operator Will Perform Well or Will Be Going Down. So That Observer Rate The Operator With Their Maximum Effort.
Finally, I Hope I am Able To Elaborate The Concept of Operator Performance Rating.



Monday, January 25, 2016

Some Important Tools in Industrial Engineering at Garments Industry & Simplify & Clarify These Tools with Short Definition. Part- iii




Qualified Worker: is a person who has the necessary physical and mental attributes, and at the same time has the appropriate skills and tools to perform the job.

One who has acquired the skill, knowledge and other attributes to carry out the work by meeting the standards of quantity, quality, & safety.

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A Multi needle Kansai Machine

Time:  The length of time taken to complete the job, usually expressed as labor standard or standard time.

Normal Working Condition: The acceptable working environment in terms of temperature, humidity, lighting, noise, etc. needed to perform the job.

Time Study: Time Study is a process for measuring the required time for performing a given task by a given method by a trained worker working in a normal pace.

It is a procedure to determine a certain amount of time required to perform a task involving either human or machine under certain standard conditions of measurement which consider

1.    Specified Work.

2.    Well Trained Worker.

3.    Normal Pace.

4.   Allowance.
Time Study is the development of a standard time by observing a task an analyzing it with the use of a stopwatch. 


SMV: SMV means Standard Minute Value.



Standard Minute Value is a numerical value which is represented the standard time of a process or operation in a standard environment for standard worker.


Standard Time is a total time in which a job should be completed of a standard performance.

SMV= It should be expressed always in minutes.

=  Time taken from a standard operator to complete any given operation with pre-define condition.

The amount of time a qualified worker should spend to complete a specified task, working at sustainable rate, using given methods, and equipment, raw materials and workplace.
Standard Time = (Average Observe Time × Rating) + Allowance.

Allowance: Different types of allowance are allowed in apparel production floor, such as personal time allowance, delay allowances, fatigue allowances, etc.

Cycle Time: Total time taken to do all works to complete one operation i. e; time from pick up part of first piece to next pick up of the next piece.



Md. Farid Ahmed
IE Officer
Fakir Apparels Ltd.
BSCIC Industrial Area, Enayet Nagar,
Fatulla, Narayangonj, Bangladesh.
Contact : +8801814220987
Email: farid.ieconcern@gmail.com

Friday, January 22, 2016

Some Important Tools in Industrial Engineering at Garments Industry & Simplify & Clarify These Tools with Short Definition. Part- ii



MethodStudy: Method Study is a systematical recording and critical examination of ways of doing things in order to make improvement.

Method Study is the Process of subjecting work to systematic, critical scrutiny to make it more effective and/or more efficient. It is one of the keys to achieving productivity improvement.

That is

It is a systematic recording and critical examination of existing and proposed ways of doing work, as a means of developing and applying easier and more effective methods and reducing costs.


Motion Study: Motion Study involves the analysis of the basic hand, arm and body movements of workers as they perform work.


Motion Study is designed to determine to best way to complete a repetitive job.

That is

Motion Study Measures distance or how much you move to do a job and how much you get done in a period of time.

Work Measurement: Work Measurement is concerned with investigating, reducing and eliminating ineffective time, whatever may be the cause.

Determine the time necessary to perform a job and its elements.

The application of technique designed to establish the time for a qualified worker to carry out a specified task when working in a defined condition.
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 Md. Farid Ahmed
IE Officer
Fakir Apparels Ltd.
BSCIC Industrial Area, Enayet Nagar,
Fatulla, Narayangonj, Bangladesh.
Contact : +8801814220987
Email: farid.ieconcern@gmail.com