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.
