balancing exercise for garment industry

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Adithy Kottangal Adithy Kottangal

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Page 1: Balancing exercise for garment industry

Adithy KottangalAdithy Kottangal

Page 2: Balancing exercise for garment industry

IntroductionIntroduction

What is Line Balancing?What is Line Balancing?

Line Balancing is the technique of Line Balancing is the technique of planning sufficient work load to each planning sufficient work load to each operator to achieve required output.operator to achieve required output.

Page 3: Balancing exercise for garment industry

Line Balancing includesLine Balancing includes

Everyone is doing the same amount of Everyone is doing the same amount of wok.wok.

Doing the same amount of work to Doing the same amount of work to customer requirementcustomer requirement

Variation is smoothedVariation is smoothed No one over burdenedNo one over burdened No one waitingNo one waiting Everyone working together in balanced Everyone working together in balanced

fashion fashion

Page 4: Balancing exercise for garment industry

Introduction : What is Line Introduction : What is Line Balancing?Balancing?

Page 5: Balancing exercise for garment industry

Introduction : What is Line Introduction : What is Line Balancing?Balancing?

Page 6: Balancing exercise for garment industry

When is the Line Balancing When is the Line Balancing required?required?

Before starting a new styleBefore starting a new style While the style is being producedWhile the style is being produced

Everyday when the production starts or Everyday when the production starts or more than one time a day, it depends on more than one time a day, it depends on the situation the situation

Page 7: Balancing exercise for garment industry

Line Balancing depends on;Line Balancing depends on;

Performance of the individualsPerformance of the individuals Work in progressWork in progress AbsenteeismAbsenteeism Labour turnoverLabour turnover Management efficiencyManagement efficiency

Page 8: Balancing exercise for garment industry

AdvantagesAdvantages

Line Balancing is an effective tool to improve the Line Balancing is an effective tool to improve the through put of assembly line while reducing man through put of assembly line while reducing man power requirements and costspower requirements and costs

It results in less work in processIt results in less work in process Assembly line balancing ensures:Assembly line balancing ensures:

1.1. The minimization of the number of work The minimization of the number of work stationsstations

2.2. The minimization of cycle timeThe minimization of cycle time

3.3. The maximization of work load The maximization of work load smoothnesssmoothness

4.4. The maximization of work relatednessThe maximization of work relatedness

Page 9: Balancing exercise for garment industry

ProblemsProblems When assigning different tasks to When assigning different tasks to

individual workstations sum of task time individual workstations sum of task time at any stations should not exceed the at any stations should not exceed the station time.station time.

Potential bottlenecks and work imbalancePotential bottlenecks and work imbalance Machinery failureMachinery failure Slow operators and absenteeism may Slow operators and absenteeism may

interrupt the work flowinterrupt the work flow The change of operator efficiency during The change of operator efficiency during

real time production is the main reason real time production is the main reason that causes production line imbalancethat causes production line imbalance

Page 10: Balancing exercise for garment industry

Solution for ProblemsSolution for Problems

Cross train operators to perform Cross train operators to perform more than one operationmore than one operation

Substitute machines must readily Substitute machines must readily available for immediate replacement available for immediate replacement if equipment breaks downif equipment breaks down

Reroute work, shift personal or Reroute work, shift personal or reschedule to avoid delaysreschedule to avoid delays

Page 11: Balancing exercise for garment industry

EngineeringEngineering

Operation bulletin and machine Operation bulletin and machine specificationsspecifications

o Article details Article details o No of operations involvedNo of operations involvedo Types of machines usedTypes of machines used

Dividing the line in to two partsDividing the line in to two partso Preparation areaPreparation area

Small parts attachment Eg : Zipper to Small parts attachment Eg : Zipper to flyfly

o Assembling areaAssembling area

Assembling the garment Eg : Planning Assembling the garment Eg : Planning attachmentattachment

Page 12: Balancing exercise for garment industry

SMVSMV

Visually absorbing the time taken by Visually absorbing the time taken by the operator for the specific taskthe operator for the specific task

Repeating the exercise for number Repeating the exercise for number of time of time

Standardizing the value Standardizing the value Calculating the SMV of garmentCalculating the SMV of garment Forecasting the productionForecasting the production Implementing on the lineImplementing on the line

Page 13: Balancing exercise for garment industry

Calculating number of operators Calculating number of operators required for each operationrequired for each operationo Balance the line by adjusting the Balance the line by adjusting the

number of operators tact time (TOPS)number of operators tact time (TOPS) EfficiencyEfficiency

o Production @100%Production @100%o Production at present efficiencyProduction at present efficiencyo Implement the betterment on the lineImplement the betterment on the line

Page 14: Balancing exercise for garment industry

Example Example Coin pocket hem takes 0.16 minutes and Coin pocket hem takes 0.16 minutes and

requires one machine with the target of requires one machine with the target of 375 pieces, the next operations in the 375 pieces, the next operations in the preparation area is coin pocket preparation area is coin pocket attachment on the facing takes 0.35 attachment on the facing takes 0.35 minutes with the target of 171 pieces minutes with the target of 171 pieces @100% efficiency. Working time is 8 @100% efficiency. Working time is 8 hours. According to TOPS, operator hours. According to TOPS, operator required for the first operation would be required for the first operation would be 0.68=1 but the operator required for 0.68=1 but the operator required for the second operations would be1.5=2.the second operations would be1.5=2.

Page 15: Balancing exercise for garment industry