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APPC ASSIGNMENT-3
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INDUSTRY VISIT REPORT
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HIMANSHU SHEKER, SURAJ KEDIA
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Daily target
Efficiency Target per day Target per hour
100 575 72
90 518 65
80 460 58
70 403 50
60 345 43
They work at efficiency of 60% so target per day is 345 pcs
On the day of visit they produced 321 pcs in the line , less than the daily
i.e 345 pcs
WIP CALCULATION
Number of Operation Description WIP
Operations
1 Front Panel Marking for Pintuck
Making
3 Pintuck Making 24
1 Neck Frill Fold 4
1 Neck Frill Shell and Lining Run 6
Stitch
1 Side Panel Attach 3
1 Shoulder Attach at Shell 3
1 Shoulder and Side Panel Overlock 2
1 Shoulder attach at Lining with 12
Piping Joint
2 Neck and Armhole Run Stitch 4
1 Neck Frill Gather Making 16
2 Neck Frill Attach 6
1 Placket Attach 5
1 Placket Finish with Edge Stitch 4
1 Side Attach at Shell and Lining 7
1 Side Pintuck Seam at Lining 8
1 Sleeve Opening Fold 5
1 Sleeve Gather Making 13
1 Sleeve Attach 11
1 Armhole Overlock 4
1 Armhole Top Stitch 3
1 Neck Binding 8
1 Neck End Close 4
1 Lining Bottom Fold 6
TOTAL WIP
158
WIP FOR THE DAY - 158
Material flow
The pieces flow in form of a bundles with manual labour (helper) in one direction
with with an end-line inspection. So it is a one-way flow of materials.
OPERATOR ALLOCATION
Operators are allocated by industrial engineers and supervisors on the basis of the
skill & efficiency of the operators. They dont have any formal skill matrix sheet. it
takes 3-4 hours for line balancing depending upon the complexity of style.
Sewing line capacity (In pcs)
No. of sewing machines in the line= 32
Workers absence percentage of that line= 5%,
Daily working hours of that factory= 10
Line efficiency of that factory= 60%,
Standard allowed minutes (SAM) for the style= 34
Sewing line capacity= [{(32* 10 *60) 5 %} * 60%] / 34
= 443 pcs
CMT CALCULATION
SMV of the garment= 34 mins
No. of operator used= 33
Salary of each operator= Rs. 9,000/month
=Rs. 346/day
= Rs. 34.6/hour
LABOUR COST PER MINUTE= Rs.0.58
CMT COST= ( SAM of the garment * minute cost of the labour)/ (line efficiency %)
CMT of the garment= 34 * 0.58/ 60 %= Rs.32.68
Causes of lowest efficiency in Layout Plan
- No skill inventory chart
- Lack proper training & improvement programme.
- Lack of compliance issues.
-Operators absenteeism.
- More allowance time.
- Machine break down.
- Failure in Time study calculation.
-Improper supervising of sewing line etc.
Steps needed to improve efficiency
- Conducting motion study and correcting faulty motions.
- Hourly operator capacity check.
- Use best possible line layout by skill matrix
-Reduce line setting time.
-Improve line balancing
-Use work aids, attachments, guides, correct pressure foots and folders.
-Continuous feeding to the sewing line.
- Training for Line supervisors. .
-Setting individual operator target.
- Eliminate loss time and off-standard time.
-Real time shop floor data tracking system.
- Inline quality inspection at regular interval.
-Operator motivation.
- Plan for operators Incentive scheme
FORMS THAT ARE FILLED FROM THE LINE