Thesis/ project worked on increased the efficiency & productivity of a sewing line by using working aids

1. WELCOME TO OUR
PROJECT
PRESENTATION

2. PROJEC TITLE
Increasing the productivity and efficiency of a
sewing line in an apparel manufacturing industry by
adding working aids in sewing machine.

3. GROUP MEMBER :
NAME ID
GOLAM RABBY SHAWON 13.02.06.076
MAZEDUL ISLAM SOYEB 13.02.06.088
A. M. SHAKIRUL HAMID 13.02.06.127

4. Supervised By:
Dr. Md. Rafiqur Rashid
Associate Professor, DTE
Dr. Lal Mohan Baral
Professor, DTE

5. INTRODUCTION

6.  Bangladesh is a fast growing economy powered by the
readymade garments (RMG) industry which has
promoted the country in the world through the tag
‘Made in Bangladesh’. The RMG industry has become
one of the life lines of Bangladesh economy, sharing a
major part of the country’s export earnings.
 In the apparel industry sewing section is known as the
heart of a garments. After receiving all the component
of garments parts from cutting section, then those parts
are linked by sewing machine.

7.  To increase the productivity, increase in sewing line
efficiency is must. Efficiency and Productivity of a
sewing line can be increased by using various method.
By adding working aids in sewing machine efficiency
of a sewing line can be increased
 In this section manufacturer finally get a
complete appearance therefore, sewing Section is
very important department in the garments industry.

8. Objective :
 To know the function of working aids are used in
garments industry.
 To identify the scope in a sewing machine where
working aids can be used.
 To use working aids in a sewing machine and increase
the productivity, efficiency and the product quality.
 To compare the efficiency before using working aids
and after using working aids.

9. Previous Work :
• In 2015, Harshada Upasani, Pranjali Chandurkar,
Dipaksingh Girase, and Vishnu Dorugade published a
research paper named “Productivity Improvement with
Sewing Machine Attachment.”
• In 2016, Suprit Borse, Venkatesh Shrinivasan , V.S.
Shivankar Published a journal named “Improving the
Garment Productivity by Using New Designs of
Folder.”
• In 2016, Sojib Raihan published a journal named “
Effect of sewing work in garment production.’’

10. LITERATURE
REVIEW

11. Productivity :
 productivity is defined as the efficient use of
resources- labour, capital, land, materials,
energy, information –in the production of
various goods.
Productivity= Output/Input
Garment production system :
 Progressive bundle system.
 Unit production system.
 Modular production system.

12. Factors affecting on production :
• Machine break down production of assembly line.
• Imbalance line (WIP control)
• Continuous feeding to the line
• Quality problems
• Individual operator performance level.
• Operator absenteeism
Production efficiency is a term used to describe the state
of level at which a business is producing the greatest
numbers of units while utilizing the least amount of
resources possible.
Efficiency :

13. Working aids :
The additions that can be made to basic sewing
machines are many and they come under the general
term work aids.
Function of working aids :
• To improve productivity
• To improve or maintain quality
standards
• To reduce handling time.
• To minimize fatigue for the operator.

14. Different types of working aids :
Guide :
Figure : Different types of guide.
Folder :
Figure : Different types of folder

15. Compensating foot :
Figure: Compensating foot.
Specialized pressure foot:
Figure:Some special pressure foot.
Light:
Figure : Light in sewing machine.

16. Time study :
Time study is a method of direct observation. A
trained observer watches the job and records data
as the job is being performed over a number of
cycles.
Steps in Making Time Study :
• Collect all information concerning job to be
measured.
• Divide job into elements
• Determine no of cycle of time
• Extending observed times to basic times
• Determine all allowances
• Calculate standard time for job

17. PRODUCT
DESCRIPTION

18. Specification of Product :
Parameters Description
Buyer Name H&M
Order No 111051-9984
Item Tom Printed Short
Style Swim Short
Style No 0426405D
Material
Reference
Mill-li-peng
Total M.P. 68
Target/ hour 117
Utilization 77%
Product picture
Product picture

19. Specification of Fabric
Parameters Description
Color AOP
Fabric Construction 𝟏𝟖𝟐 ×𝟏𝟐𝟒
𝟑𝟎×𝟑𝟎
× 58‫״‬
Fabric Consumption 100% Polyester

20. IMPLEMENTATION OF
NEW WORKING AIDS

21. Working Process Flowchart
Selection of
factory
Selection of
sewing line
Studying the
process flowchart
of line
Identifying where working
aids are already used
Implementation of new
working aids
Identifying the
operations where
new working aids
can be used
Calculation of cycle
time, productivity
and line efficiency
Again calculation of cycle
time, productivity & line
efficiency
Final result
calculation &
discussion

22. Name of some working aids those are
already in line:
• Plain guide
• 3/16 guide
• 1/16 guide
• 1 /4 Pressure foot
• Zipper foot

23. Name of the three process and newly
introduced working aids are:
Process Name Name of the guide
Tack welt to back position Hanger guide
Attach Waist belt to body T guide
Bottom hem G guide
Figure : Hanger Guide Figure : T Guide Figure : G Guide

24. Formula used for data collection are :
1. Cycle time (C.T.) of every single operation was recorder for 5 times
and then the average cycle time was calculated.
2. Normal Time (N.T.) was calculated from the following formula :
Normal time = Cycle time × Performance rating
3. Standard time was calculated from the following formula-
Standard Time = Normal Time × (1 + Allowances)
4. Standard Minute Value (SMV) was Calculated by following formula-
5. Standard Minute Value =
𝐒𝐭𝐚𝐧𝐝𝐚𝐫𝐝 𝐓𝐢𝐦𝐞
𝟔𝟎
6. Production per hour was calculated by –
Production/ hour =
𝟔𝟎
𝐒𝐭𝐚𝐧𝐝𝐚𝐫𝐝 𝐓𝐢𝐦𝐞

25. Sl
no
Operation M/C CT PR NT Allowa
nce
ST SMV Pro/
hr
Total
Pro/
hr
Liningpart
1 Join side & croch
position O/L 14.56 0.91 13.2 0.15 15.2 0.253 236 236
2 Tack elastic SNL 13.2 0.91 12 0.15 13.8 0.230 261 261
3 Attach elastic to leg
position
O/L 32.96 0.91 30 0.15 34.5 0.574 104 240
4 O/L 25.28 0.91 23 0.15 26.5 0.440 136
Preparation
5 Attach top stitch
facing to pocket bag
(4)
SNL 43.36 0.91 39.5 0.15 45.4 0.756 79
3286 SNL 41.92 0.91 38.1 0.15 43.9 0.731 82
7 SNL 38.92 0.91 35.4 0.15 40.7 0.678 88
8 SNL 43.45 0.91 39.5 0.15 45.5 0.757 79
9 Attach top stitch
facing to pocket bag
(1)
SNL 12.64 0.91 11.5 0.15 13.2 0.220 272 272
10 Close pocket bag O/L 20.16 0.91 18.3 0.15 21.1 0.351 171 306
11 O/L 25.45 0.91 23.2 0.15 26.6 0.443 135
12 Top stitch to pocket
bag ¼
SNL 28.83 0.91 26.2 0.15 30.2 0.502 119
35413 SNL 30.12 0.91 27.4 0.15 31.5 0.525 114
14 SNL 28.45 0.91 25.9 0.15 29.8 0.496 121
Data collection before implementation of new working aids :

26. Frontpart
16 Joint front rise O/L 20.16 0.91 18.3 0.15 21.1 0.351 171 171
17 T/S to front
rise
DNL 14.24 0.91 13 0.15 14.9 0.248 242 242
18 Attach pkt bag
to front
position
SNL 24.4 0.91 22.2 0.15 25.5 0.425 141
271
19 SNL 26.4 0.91 24 0.15 27.6 0.460 130
20 Shadow stitch SNL 13.12 0.91 11.9 0.15 13.7 0.228 262 262
21 T/S to front pkt
position
SNL 27.52 0.91 25 0.15 28.8 0.479 125
246
22 SNL 28.48 0.91 25.9 0.15 29.8 0.496 121
23 Tack front pkt
position
SNL 28.47 0.91 25.9 0.15 29.8 0.496 121
241
24 SNL 28.6 0.91 26 0.15 29.9 0.498 120
25 Tack front pkt
position
SNL 12.96 0.91 11.8 0.15 13.6 0.226 265 265
26 B/T to front pkt B/T 10.72 0.91 9.76 0.15 11.2 0.186 321 321
Data collection before implementation of new working aids (Cont..):

27. BackPart
27 Tack pkt bag to
back pkt
SNL 12.98 0.91 11.8 0.15 13.6 0.226 265 265
28 Join back rise O/L 20.32 0.91 18.5 0.15 21.3 0.354 169 350
29 O/L 19.04 0.91 17.3 0.15 19.9 0.332 181
30 Top stitch to back
rise
DNL 13.44 0.91 12.2 0.15 14.1 0.234 256 256
31 Top stitch to back
pkt welt
SNL 12.16 0.91 11.1 0.15 12.7 0.212 283 283
32 Tack welt to back
position SNL 18.52 0.91 16.9 0.15 19.4 0.323 186 186
33 Run Stitch to back
position SNL 12.96 0.91 11.8 0.15 13.6 0.226 265 265
34 Att Velcro to back
pkt
SNL 12.8 0.91 11.6 0.15 13.4 0.223 269 531
35 SNL 13.12 0.91 11.9 0.15 13.7 0.228 262
36 Close pkt bag
mouth
O/L 13.76 0.91 12.5 0.15 14.4 0.24 250 250
37 Join side seam O/L 28.8 0.91 26.2 0.15 30.1 0.502 119 258
38 O/L 24.8 0.91 22.6 0.15 26 0.432 139
39 Attach bottom
facing
SNL 28.45 0.91 25.9 0.15 29.8 0.496 121
38740 SNL 26.72 0.91 24.3 0.15 28 0.466 129
41 SNL 25.12 0.91 22.9 0.15 26.3 0.438 137
Data collection before implementation of new working aids (cont..) :

28. Backpart
42 Shadow stitch to
bottom
SNL 26.56 0.91 24.2 0.15 27.8 0.463 130
258
43 SNL 26.88 0.91 24.5 0.15 28.1 0.468 128
44 Tack waist belt V/T 16.8 0.91 15.3 0.15 17.6 0.293 205 205
45 Attach waist belt
to body
SNL 35.2 0.91 32 0.15 36.8 0.613 98
192
46 SNL 36.71 0.91 33.4 0.15 38.4 0.640 94
47 Make hole to
waist position
B/H 12.64 0.91 11.5 0.15 13.2 0.220 272
272
48 Tack elastic to
waist position
SNL 28.96 0.91 26.4 0.15 30.3 0.505 119
240
49 SNL 28.32 0.91 25.8 0.15 29.6 0.493 121
50 Attach T/S to
waist belt
K/S 28 0.91 25.5 0.15 29.3 0.488 123 241
51 K/S 29.12 0.91 26.5 0.15 30.5 0.507 118
52 Tack label SNL 10.72 0.91 9.76 0.15 11.2 0.186 321 321
53 Attach label to
body
SNL 11.96 0.91 10.9 0.15 12.5 0.208 288 288
54 Tack label to
waist position
SNL 11.45 0.91 10.4 0.15 12 0.199 300
300
Data collection before implementation of new working aids (cont..):

29. FinalAssembly
55 Join shell lining
to waist position
SNL 32.84 0.91 29.9 0.15 34.4 0.572 105
318
56 SNL 33.48 0.91 30.5 0.15 35 0.583 103
57 SNL 31.36 0.91 28.5 0.15 32.8 0.546 110
58 O/L to waist
position
O/L 26.24 0.91 23.9 0.15 27.5 0.457 131 257
59 O/L 27.36 0.91 24.9 0.15 28.6 0.477 126
60 T/S to label
position
SNL 13.39 0.91 12.2 0.15 14 0.233 257 257
61 Close inseam O/L 13.92 0.91 12.7 0.15 14.6 0.242 247 247
62
Bottom Heam
SNL 45.16 0.91 41.1 0.15 47.3 0.787 76
24663 SNL 42.68 0.91 38.8 0.15 44.7 0.744 81
64 SNL 43.58 0.91 39.7 0.15 45.6 0.760 79
Total SMV 26.87
Data collection before implementation of new working aids (Cont..) :

30. Tack welt to back position
Before implementation of guide :
Figure : Tack welt to back position operation before implementation of working aids

31. Hanger guide used for the process of tack welt to back position
Figure : Hanger guide
After implementation of hanger guide :
Figure : After implementation of hanger guide.

32. Attach waist belt to body :
Before implementation of guide :
Figure: Attach waist belt to body operation before implementation of working aids
T- Guide used for the process of attach waist belt to body:
Figure : T Guide.

33. After implementation of T guide :
Figure :After implementation of T guide

34. Better Sewing Quality:
Figure: with T guide
Figure: with out T guide

35. Bottom hem :
Before implementation guide:
Figure : Bottom hem operation before implementation guide
G Guide used for the process of bottom hem
Figure : G guide

36. After implementation of G guide :
Figure : Bottom hem operation after implementation of g guide.

37. Sl
no
Operation M/C CT PR NT Allowa
nce
ST SMV Pro/
hr
Total
Pro/
hr
Liningpart
1 Join side & croch
position O/L 14.56 0.91 13.2 0.15 15.2 0.253 236 236
2 Tack elastic SNL 13.2 0.91 12 0.15 13.8 0.230 261 261
3 Attach elastic to leg
position
O/L 32.96 0.91 30 0.15 34.5 0.574 104 240
4 O/L 25.28 0.91 23 0.15 26.5 0.440 136
Preparation
5 Attach top stitch
facing to pocket bag
(4)
SNL 43.36 0.91 39.5 0.15 45.4 0.756 79
3286 SNL 41.92 0.91 38.1 0.15 43.9 0.731 82
7 SNL 38.92 0.91 35.4 0.15 40.7 0.678 88
8 SNL 43.45 0.91 39.5 0.15 45.5 0.757 79
9 Attach top stitch
facing to pocket bag
(1)
SNL 12.64 0.91 11.5 0.15 13.2 0.220 272 272
10 Close pocket bag O/L 20.16 0.91 18.3 0.15 21.1 0.351 171 306
11 O/L 25.45 0.91 23.2 0.15 26.6 0.443 135
12 Top stitch to pocket
bag ¼
SNL 28.83 0.91 26.2 0.15 30.2 0.502 119
35413 SNL 30.12 0.91 27.4 0.15 31.5 0.525 114
14 SNL 28.45 0.91 25.9 0.15 29.8 0.496 121
15 Tack elastic DNL 10.29 0.91 9.36 0.15 10.8 0.179 334 334
Data collection after implementation of new working aids :

38. Data collection after implementation of new working aids :
Frontpart
16 Joint front rise O/L 20.16 0.91 18.3 0.15 21.1 0.351 171 171
17 T/S to front
rise
DNL 14.24 0.91 13 0.15 14.9 0.248 242 242
18 Attach pkt bag
to front
position
SNL 24.4 0.91 22.2 0.15 25.5 0.425 141
271
19 SNL 26.4 0.91 24 0.15 27.6 0.460 130
20 Shadow stitch SNL 13.12 0.91 11.9 0.15 13.7 0.228 262 262
21 T/S to front pkt
position
SNL 27.52 0.91 25 0.15 28.8 0.479 125
246
22 SNL 28.48 0.91 25.9 0.15 29.8 0.496 121
23 Tack front pkt
position
SNL 28.47 0.91 25.9 0.15 29.8 0.496 121
241
24 SNL 28.6 0.91 26 0.15 29.9 0.498 120
25 Tack front pkt
position
SNL 12.96 0.91 11.8 0.15 13.6 0.226 265 265
26 B/T to front pkt B/T 10.72 0.91 9.76 0.15 11.2 0.186 321 321

39. Data collection after implementation of new working aids :
BackPart
27 Tack pkt bag to
back pkt
SNL 12.98 0.91 11.8 0.15 13.6 0.226 265 265
28 Join back rise O/L 20.32 0.91 18.5 0.15 21.3 0.354 169 350
29 O/L 19.04 0.91 17.3 0.15 19.9 0.332 181
30 Top stitch to back
rise
DNL 13.44 0.91 12.2 0.15 14.1 0.234 256 256
31 Top stitch to back
pkt welt
SNL 12.16 0.91 11.1 0.15 12.7 0.212 283 283
32 Tack welt to back
position SNL 14.16 0.91 12.89 0.15 14.8 0.247 243 243
33 Run Stitch to back
position SNL 12.96 0.91 11.8 0.15 13.6 0.226 265 265
34 Att Velcro to back
pkt
SNL 12.8 0.91 11.6 0.15 13.4 0.223 269 531
35 SNL 13.12 0.91 11.9 0.15 13.7 0.228 262
36 Close pkt bag
mouth
O/L 13.76 0.91 12.5 0.15 14.4 0.24 250 250
37 Join side seam O/L 28.8 0.91 26.2 0.15 30.1 0.502 119 258
38 O/L 24.8 0.91 22.6 0.15 26 0.432 139
39 Attach bottom
facing
SNL 28.45 0.91 25.9 0.15 29.8 0.496 121
38740 SNL 26.72 0.91 24.3 0.15 28 0.466 129
41 SNL 25.12 0.91 22.9 0.15 26.3 0.438 137

40. Data collection after implementation of new working aids :
Backpart
42 Shadow stitch to
bottom
SNL 26.56 0.91 24.2 0.15 27.8 0.463 130
258
43 SNL 26.88 0.91 24.5 0.15 28.1 0.468 128
44 Tack waist belt V/T 16.8 0.91 15.3 0.15 17.6 0.293 205 205
45 Attach waist belt
to body
SNL 27.47 0.91 24.98 0.15 28.7 0.478 125
240
46 SNL 29.83 0.91 27.15 0.15 31.2 0.52 115
47 Make hole to
waist position
B/H 12.64 0.91 11.5 0.15 13.2 0.220 272
272
48 Tack elastic to
waist position
SNL 28.96 0.91 26.4 0.15 30.3 0.505 119
240
49 SNL 28.32 0.91 25.8 0.15 29.6 0.493 121
50 Attach T/S to
waist belt
K/S 28 0.91 25.5 0.15 29.3 0.488 123 241
51 K/S 29.12 0.91 26.5 0.15 30.5 0.507 118
52 Tack label SNL 10.72 0.91 9.76 0.15 11.2 0.186 321 321
53 Attach label to
body
SNL 11.96 0.91 10.9 0.15 12.5 0.208 288 288
54 Tack label to
waist position
SNL 11.45 0.91 10.4 0.15 12 0.199 300
300

41. Data collection after implementation of new working aids :
FinalAssembly
55 Join shell lining
to waist position
SNL 32.84 0.91 29.9 0.15 34.4 0.572 105
318
56 SNL 33.48 0.91 30.5 0.15 35 0.583 103
57 SNL 31.36 0.91 28.5 0.15 32.8 0.546 110
58 O/L to waist
position
O/L 26.24 0.91 23.9 0.15 27.5 0.457 131 257
59 O/L 27.36 0.91 24.9 0.15 28.6 0.477 126
60 T/S to label
position
SNL 13.39 0.91 12.2 0.15 14 0.233 257 257
61 Close inseam O/L 13.92 0.91 12.7 0.15 14.6 0.242 247 247
62
Bottom Heam
SNL 35.78 0.91 35.78 0.15 41.1 0.685 87
26863 SNL 33.83 0.91 33.83 0.15 38.9 0.648 93
64 SNL 35.64 0.91 35.64 0.15 41 0.683 88
Total SMV 26.27

42. CALCULATION

43. Before implementation of new working aids:
Given Minute = Working Hour × 60 × No. of Operators
= 8 × 60 × 68
= 32640
Earned Minute = Production/hr × Working Hour × SMV
= 117 × 8 × 26.87
= 25150.32

44. Efficiency =
Earned Minute
Given Minute
× 100
=
25150.32
32640
× 100
= 77.05 %
Production =
Total No.of Worker × Working hour per day × 60× Efficiency
Total SMV
pieces/shift
=
68 × 𝟖 × 𝟔𝟎 × 𝐨.𝟕𝟕𝟎𝟓
26.87
Pieces /shift
= 936 Pieces/ shift
= 117 Pieces/ hour

45. After implementation of new working aids:
Given Minute = Working Hour × 60 × No. of Operators
= 8 × 60 × 68
= 32640
Earned Minute = Production/hr × Working Hour × SMV
= 120 × 8 × 26.27
= 25223.04

46. Efficiency =
Earned Minute
Given Minute
× 100
=
25223.04
32640
× 100
= 77.28 %
Production =
Total No.of Worker × Working hour per day × 60× Efficiency
Total SMV
pieces/shift
=
68 × 𝟖 × 𝟔𝟎 × 𝐨.𝟕𝟕𝟐𝟖
26.27
Pieces /shift
= 960 Pieces/ shift
= 120 Pieces/ hour

47. Graphical representation of production/shift
936
960
920
925
930
935
940
945
950
955
960
965
Before After
Production/Shift

48. Graphical representation of sewing line efficiency:
77.05%
77.28%
76.90%
76.95%
77.00%
77.05%
77.10%
77.15%
77.20%
77.25%
77.30%
Before After
EfficiencyofTheLine

49. Change in Cycle time
Sl No Operation Name Man
Pow
er
Cycle Time Reduced
CT
(second)
Before After
01 Tack welt to back
position
1 18.52 14.16 4.36
02 Attach waist belt to body 2 71.91 57.3 14.61
03 Bottom hem 3 131.42 115.66 15.76

50. Cycle time between before and after using working aids
0
20
40
60
80
100
120
140
Tack welt to back
position
Attach waist belt to
body
Bottom hem
18.52
71.91
131.92
14.16
57.3
115.66
CycleTime
Operation Name
BEFORE IMPLEMENTING WORKING AIDS AFTER IMPLEMENTING WORKING AIDS2

51. Change in Standard minute value (SMV)
Sl
No Operation Name
Man
power
SMV Reduced
SMV
(%)
Before After
01 Tack welt to back
position
1 0.32 0.247 21.87
02 Attach waist belt to body 2 1.25 0.998 20.16
03 Bottom hem 3 2.29 1.99 13.10

52. SMV between before and after using working aids
0
0.5
1
1.5
2
2.5
Tack welt to
back position
Attach waist
belt to body
Bottom hem
0.32
1.25
2.29
0.247
0.998
1.99
SMV
Operation Name
BEFORE IMPLEMENTING WORKING AIDS AFTER IMPLEMENTING WORKING AIDS2

53. Change in Production/hour:
Sl
No Operation
Name
Man
powe
r
Production/
Hour
Increased
Pro/ hr
(Percentage)Before After
01 Tack welt to back
position
1 186 243 30.64
02 Attach waist belt
to body
2 192 240 25
03 Bottom hem 3 236 268 13.10

54. Pro/Hr between before and after using working aids
0
50
100
150
200
250
300
Tack welt to back
position
Attach waist belt
to body
Bottom hem
186 192
236243 240
268
Production/Hour
Operation Name
BEFORE IMPLEMENTING WORKING AIDS AFTER IMPLEMENTING WORKING AIDS2

55. RESULTS

56. Result
• SMV has been reduced from 26.87 to 26.27
• Production has been increased from 117 to 120 pieces per hour
• Production increase rate = 2.56%
• Efficiency has been increased from 77.05% to 77.28%

57. Limitations
1. Unable to replace ineffective operators.
2. Some workers were uncomfortable when we
were observing them.
3. Unable to replace less effective machine.

58. Conclusion :
After using new working aids in the sewing line, a better result was
achieved. After implementation of three types of working aids for
three process it was able to reduce the cycle time and SMV. So that the
production was increased by 3 pieces/ hour. Line efficiency has been
increased from 77.05% to 77.28 % .
Now a days working aids has significance effect on productivity. By
using working aids efficiency of the sewing line can be increased and
worker can complete his or her work more effectively.

59. THANK YOU ALL