new age garments final_presentation

SEWING RESEARCH INSTITUTE

JUKI Machinery Bangladesh Ltd.

Presentation for New age Garments Ltd.

Saidur RahmanPlant Engineer,JUKI

Saad Bin A.RashidPlant Engineer,JUKI

Presented by:


©2010 JUKI Corporation

- Exercise -

No.1 No.2 No.3 No.4 No.5



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No.1

No.2

No.3

No.4

No.5

Exercise-1



Exercise-1



Result

Balance Layout OutputWork inProcess

1 × ○ 14 25

2

3



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No.1

No.1

No.5

No.2

No.3

No.3

No.4

No.4

No.２

No.5

Exercise-2



Exercise-2



Result


1 × ○ 14 25

2 ○ × 18 8

3



Exercise-3

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No.1

No.2

No.3

No.4

No.5



Exercise-3



Result


1 × ○ 14 25

2 ○ × 18 8

3 ○ ○ 25 6



Line Balance

Operator1

Operator2

Operator3

Operator4

Operator5

5letters

2 letters

8 letters

3 letters

7 letters

5 letters

100% Efficiency!



What is productivity?

Target daily capacity ＝

Daily work hours ×Number of workers

Net total ×Processing time

（１＋Allowance rate）

× Organization efficiency


Executive Summery:

Line 1;

Product : Casual shirt

Executive summary


CONDITION OF SEWING LINE Existing 85% Effeciency

Daily work time (in sec) 36000 Sec (10 Hours)

Number of workers70 (26 Helpers, 44

Operators) (37.14% Helper)

Allowance rate 24.7%

Net total processing time (sec) 1445 sec (24 min 6 Sec)

Daily production Pcs (8 Hours)861 Pcs,

(Per Hour 87 Pcs)1172 pcs(per hour

118 pcs)

Day wise productivity (pcs/worker) pc / worker

Line Condition



Existing Layout

A01

A02

B03

B04

A08

C02

C05

C03

C09

D01

E08

A04

QC

A06

B02

A08

C06

E0 4

E06

A03

A05

A07

B01

C01

C07

E01

E05

C04B05

QC

C08

C10

D02,D03

E02

E02

E03

E07

E09

E08E09

QC

E10

E12

E12

E13

E13

E14

E15

E15

E16

E18

E18

E19

E19

E20

E21

E22

E2 3

E26

E27

E27

E24

E25

F01Iron

E20

E11

G03

E17



A01

A02

B03

A08

C02

C05

C03

C09

D01

E08

A04

QC

A06

B02

A08

E01

E04

E06

A03

A05

B01

C01 C04

QC

C10

D02,D03

E07

E09

E08E09

QC

E10

E12

E12

E13

E13

E14

E15

E15

E1 6

E18

E18

E19

E19

F02

E21

E22

E23

E26

E27

E27

E25

E20

E17

A07

B04

B05

C06

C0 7

C08

G01

G02

G03

E02

E03 E05

E02

E11

E20

F01

Improved Layout

SEWING RESEARCH INSTITUTEHow many stitching hours/day?

10 hours

1.5hoursStitching

5.5hoursPick up & dispose

3hoursWastage!!!

Increase stitching time = increase output

Your Factory Allowance 24.7%

©2013 JUKI Machinery Bangladesh Ltd.



Allowance : 24.7%

©2011JUKI Corporation

0.0 %

0.5 %

1.0 %

1.5 %

2.0 %

2.5 %

3.0 %

3.5 %

4.0 %

4.5 %

Your factory Japan Average *Average of investigation of 333 factory by JUKI

0.0 %

10.0 %

20.0 %

30.0 %

40.0 %

50.0 %

60.0 %

70.0 %



Line Balance 62.4%


05

10

15

20

25

30

35

Pro

ce

ss T

ime

(s

ec

.)

Process Name (Operator No.)

24.23

16.97

20.6



Improvement Idea



Reduce Bottle Neck

Attach Back Yoke Sew shoulder

Work can be shared to reduce bottleneck

SEWING RESEARCH INSTITUTEButton Attach Position

©2011 JUKI CorporationMark Button Attach Position


Button stitch gauge

Reduce Marking Operation

SEWING RESEARCH INSTITUTECollar making

©2011 JUKI CorporationExisting

Improvement idea

SEWING RESEARCH INSTITUTEMark Center position

Existing(10sec)Existing(12sec)



Topstitch sleeve

Existing( 39 sec+37 sec)= 76 sec

Improved (42 sec)



Attach sleeve

Existing( 28 sec+24 sec)= 52 secImproved (37 sec)

SEWING RESEARCH INSTITUTECrease sleeve hem


Existing Improvement idea


CONDITION OF SEWING LINE Existing Kaizen line

Daily work time (in sec) 36000 Sec (10 Hours)36000 Sec (10

Hours)

Number of workers70 (26 Helpers, 44

Operators) (37.14% Helper)66 (22 Helpers, 44 Operators)

Allowance rate 24.7%24.7%

Net total processing time (sec) 1445 sec (24 min 6 Sec)1431 sec (23 min

40 Sec)

Daily production Pcs (8 Hours)861 Pcs,

(Per Hour 87 Pcs)995 pcs

(per hour 99 pcs)

Day wise productivity (pcs/worker) 12 pc / worker 15 pc / worker

Kaizen Line Condition

SEWING RESEARCH INSTITUTESummary (At a glance)

Process Process Before Reduce(Proposed)

Mark Front Part Mid Point(A08)

Mark Placket Join Position(A09)

1+1 0

Mark Button position(E24)

2 2

Attach loop(C03) Mark Centering position(C04)

1+1 1

Total: 3 Helper Can possible to Reduce



05

10

15

20

25

30

35

Pro

ce

ss T

ime

(s

ec

.)

Process Name (Operator No.)

Kaizen Line Balance 74.6%



Visual management

E08

QC

E10

E12

E1 2

E13

E13

E14

E15

E15

E1 6

E18

E18

E19

E19

E20

E21

E22

E23

E26

E2 7

E27

F01Iron

E20

E11

G03

E17



Visual management



Reduce Allowance



KAIZEN (=Improvement)

It is ok…Don’t take itso seriously

Hesitate!!

All we need todo it is to makeSmall improvementslittle by little

It is a tough job.I cannot do it.



OJT seminar (On the Job Training)



Automatic machine

new age garments final_presentation

Documents

stitching time

net total processing

effeciencydaily work

factory japan average

helperallowance rate

hours861 pcs

rashidplant engineer

average of investigation