PRODUCTIVITY IMPROVEMENT BY LINE BALANCING

ON JACKET

PREPARED BY: Melkamu worke

ID NO. 1298/03
SUBMMITTED TO: Berihun
SUBMMITION DATE:
BIFG-M APPAREL AND GARMENT PLC

ba 2006
Bahir dar university (EITEX) Prepared by: melkamu worke 4th GED
 Table of Contents
PRODUCTIVITY IMPROVEMENT BY LINE BALANCING....................................................................1
Declaration....................................................................................................................................2
Student: Melkamu worke..............................................................................................................2
Executive Summary.......................................................................................................................4
Raw materials, accessories and other input to the company............................................................19
Introduction................................................................................................................................22
Significance of the Project...........................................................................................................26

ba 2006
Bahir dar university (EITEX) Prepared by: melkamu worke 4th GED
 Declaration

I declared that this internship report is submitted by me. I assure that the report contains
actual data and project I assigned to work on the intern ship stay. The content of the report
are my own and has not been submitted to any other university or institute.

Date ___________________________________________

Signature_______________________________________

Signature_______________________________________

Mentor Ins. Berihun

Student: Melkamu worke

ba 2006
Bahir dar university (EITEX) Prepared by: melkamu worke 4th GED
 ACKNOWLEDGMENT

I take this opportunity to express my profound gratitude and deep regards to my guide
(production manager Mr. Michael), (designer Woynshet m) and my (mentor Berihun) for
their exemplary guidance, monitoring and constant encouragement throughout the course of
this thesis. The blessing, help and guidance given by him time to time shall carry me a long
way in the journey of life on which I am about to embark. I also take this opportunity to
express a deep sense of gratitude to company mentor name, designation company name, for
his cordial support, valuable information and guidance, which helped me in completing this
task through various stages. I am obliged to staff members of (company name), for the
valuable information provided by them in their respective fields. I am grateful for their
cooperative during the period of my project. Lastly I thank almightily, my parents, brother,
sisters and friends for their constant encouragement without which this project would not be
possible.

ba 2006
Bahir dar university (EITEX) Prepared by: melkamu worke 4th GED
 Executive Summary

This final report covers my internship practice which I have been working in BIG- m garment
factory from March, 2014 up to June 2014. For the past three and half months. This report
has different section and also discusses about each departments. The report covers three
chapters,

Chapter one: discusses about the historical background of the company, customers,
products, location, mission, and vision value and swot analysis. Organizational structure and
also discusses about main departments of this company.

Chapter two: discusses about project works on productivity improvement through line
balancing in Big-m garment factory. In this title discusses about objective of the project,
statement of the problem, scope of the project, significance of the project, , methodology,
result and discussion and finally conclude this project.

Chapter three: discusses about internship experience, recomemndationand conclusions.

ba 2006
Bahir dar university (EITEX) Prepared by: melkamu worke 4th GED
 CHAPTER ONE

1. ORGANIZATIONAL BACKGROUND
1.1. INTRODUCTION

Big apparel and garment manufacturing was founded in 2004 E.C in Addis Ababa around kaliti .in
the space of 7977square feet. Big apparel and garment company is one of the sister companies of
MIDROC of sheikh Mohammed Hussein almoudy and Mr. Elias meshesha for the purpose of to
carry woven and knit garment and also the selection will range from the basics to the stylish
western wear. In order to fit the target market base sales representative will purchase Varity of
sizes colors and styles. The management will rely on customer feedback suggestions and sales
report to introduce or eliminate certain brands .styles and sizes. The products produced by big
apparel are coat, jacket, shirt, trouser, long dress, hair cover, masks, bags, shoeshine, and much
more up on specific request. Among the criteria’s that makes BIG apparel makes differentiate from
others are it maintains detailed record on each customer base while logging address, purchase size
and brand for customer follow up the location of the company is central to its target customers
base and on time delivery and fit of offer are manifests its strength from others. Big- M apparel
and Garment Company will use a target advertising and sales program to generate publicity and
build customer base awareness some of the mean’s that big apparel applies are

 Broachers
 News paper
 Business cards, TV and radio
 Social networking

Big-M also out sourcing shop for merchandize with manufacturers who have a regional
representative show room located at Mercator business center in addition to that it is also
solidify relationship with largest and leading manufacturers and exporters of garmenting and
accessories and tailoring material from china.

ba 2006
Bahir dar university (EITEX) Prepared by: melkamu worke 4th GED
 the technology used by the company advanced be utilize to maintain stock levels and track
sales it also use peach tree accounting software for financial and accounting purpose for
inventory management and point of sale transaction utilize inventory control expert
software and being window based software allows managing ones inventory and point of sale
functions all in one the business plan will be generated and reviewed on annual basis by
using the most prominent and update version of business plan program .

There are 380 peoples in Big-m apparel and garment plc.;

Vision

To become a number one reference in the Ethiopian garmenting industry and abroad.

Mission

Offering quality style and named brand in an assortment of sizes to accommodate all varying
body shapes.

Objectives
To Creating best shopping environment that caters to the apparel needs of the urban and
rural.

To earn 80 % of market share and building powerful brand recognition

To achieve and receive a profit m

Value

Creating employment opportunity, acquiring skill developed communicated and motivated

employees with good working habit or culture and also producing different type’s quality
garments

ba 2006
Bahir dar university (EITEX) Prepared by: melkamu worke 4th GED
 1.2 ORGANIZATIOL CHART FOR BIG-M APPAREL AND GARMENT
PLC

MANAGING
DIRECTOR

BUSINESS GENERAL EXCUTIVE

MANAGER SECRETARY
CONSULTAN
T

DEPUTY
MANAGER

DESIGN PRODUCTIO ADMINSTRA SALES AND FINANCE RECIVING,

MERCHANDISE N TION MARKETING SHIPING
AND BILL OF
MATERIAL

Human Promotion
Store
SCREEN resource
PRINTING

CUTTING

SEWING

MAINTAINANCE

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Bahir dar university (EITEX) Prepared by: melkamu worke 4th GED
 1.3 Machines available in Big- m apparel and their origin

N Make Model DESCRIPITION Machine QUANTIT

o origin Y
1 Juki DDL-8300N 1needle lock stitch machine china 183
2 Juki DDL-8700-7- 1needle lock stitch under china 50
WB/AK85/SC910/M trimmer with EE10BT motor
911CP160
3 Juki MO-670450E44OH 1needle three thread server china 25
4 Juki MO- 1 needle three thread Mack china 65
6714SBE644H/G39/ safety stitch machine
Q141
5 Juki MO-6716SDE64OH 2needle 5-thread safety stitch china 12
machine
6 Juki MB-373NSOOS Chain stitch button server china 14
7 Juki LBH-781U Lock stitch button hole stitch Japan 14
8 Juki LBH-780U Incl knife for cutting 6,4 to 38 Japan 6
9 Juki MS-1190D Feeds of arm 2-needle chain Japan 9
stitch
1 Juki MH-382U dabble needle chain stitch Japan 2
0
1 Juki LH-3128(WITH Electronic bar-tack machine Japan 8
1 CENTERE KNFE
ATTACH)
1 Juki LK-1900ASS0000 2-needle lock stitch machine Japan 8
2
1 Juki/cam MF-7823-U10-B64 3needle top &bottom cover Japan 12
3 ion stitch cylinder 64mm
special
1 Juki MF-760ST-UO6- 3needle top &bottom cover Japan 44
4 B64/HOL-B48 stitch hated bed 6,4/48mm

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Bahir dar university (EITEX) Prepared by: melkamu worke 4th GED
 1 Ks DFB-1404P For short front Japan 2
5
1 Ks DFB-1404P For waist band USA 2
6
TOTAL 456

1.3.1 NUMBER OF MACHINES IN CUUTING ROOM AND PRINT

ITEM NAME AND PURPOSE OF THE MACHINE Quantity
NUMBER
1 Fabric inspection machine 1
For yardage identification
And defect identification
2 Straight knifes 3
For the purpose of lay cutting
3 Band knife 1
For the purpose of cutting but it is an ideal
position
4 Fueling machine 4
To fuse of entering of small components
5 End cutter 1
For the purpose of cutting the end of pug
Printing 10
1 4head rotary machine 1
Hold different screens
2 Heater(dryersoftener –to fasten the print) 2
To drag the paste on the print
3 1

1.4 WORKING PROCEDURES OF BIG-M Apparel

Order receiving

ba 2006
Bahir dar university (EITEX) Prepared by: melkamu worke 4th GED
 Design/sketch

Pattern design

Sample making

Costing

Fabric cost
Making changed
profit
Trimming/findings

Production pattern

Marker making

Spreading

Cutting printing

Sorting and
building

Sewing

Online inspection

Trimming

Ironing

Final inspection

Dispatch

1.5 Product variety of the company

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Bahir dar university (EITEX) Prepared by: melkamu worke 4th GED
 ba 2006
Bahir dar university (EITEX) Prepared by: melkamu worke 4th GED
 l

ba 2006
Bahir dar university (EITEX) Prepared by: melkamu worke 4th GED
  Working cloths like coverall , over coat
 Safari coat
 Nurse clothes
 Trousers
 Dresses
 Different capes
 Sari an coat
 Children’s clothes
 uniforms

1.5 WORKING PROCESS OF BIG-M GARMENT FACTORY IN EACH

DEPARTMENT
1.5.1 DESSIGN/SAMPLING DEPARTMENT

Design department is organized in both 12 machines and five sample operators. From
this six of them are single needle lock stitch machines
, One west band machine, one button attaching machine, one over lock and one bar
tuck machine
In this department when the customer brings sample the designer develops pattern for
the given sample then the designer receives the fabric from the store make sample
based on customers specification sheet. The designer should prepare two samples one
for customer and the other for the factory or used for mass production.
After the customers approve the design sample the designer generates the production
pattern according the specification made before.

ba 2006
Bahir dar university (EITEX) Prepared by: melkamu worke 4th GED
 The major activities of sampling department department:-

Order receiving with specification

Level of pattern for the sample
Receive fabric from the store
Make sample for the customer based on specification
Send to the customer for approval
Costing

Production pattern

1.6 CUTTING SECTION

In cutting section there are ten workers three of them are cutters and marker makers and also
three spreadnes,2 dispatching and for the purpose of numbering .

In cutting department the number of machines available is:-

Oshima:-for the purpose of measuring yardage of the fabric and inspection of fabric defected.

Straight knife:-for the purpose of cutting

End cutter and band knife:-even if the machine available but for the time being is out for
work due to lack of maintenance.in addition to this there is also semi-automatic spreader
machine out of working due to the lack of maintenance at the same time.

The major activities in cutting department are:-

 Marker making
 Spreading
 Cutting
 Numbering of the cutting parts

ba 2006
Bahir dar university (EITEX) Prepared by: melkamu worke 4th GED
  Sorting and bundling
 Dispatch or give to the line supervisor.

1.6.1 Work flow process of cutting department

Fabric receive from the store

Marker on single fabric

Fabric spread (n-1)

Marker placed at the top of the spread

Fabric cut

Numbering of the cut parts

Sorting/bundling according to sizes

Inputted to sewing department

1.6.2 Cutting department draw backs

 Absence of precision cut parts

 Absence of consistent cutting (absence of uniformity)
 Absence of communication with patterns and other departments
 High amount of fabric wastage due to lack of fabric efficiency-

ba 2006
Bahir dar university (EITEX) Prepared by: melkamu worke 4th GED
 1.7 Sewing department
As we know sewing plays vital role for garment production. In big-M Garment
factory follows progressive bundling production system .the sewing department
consists of 10 Working lines and 14 non-working lines, from 14 non-working lines
10s are equipped with juke sewing machines the rest 4 are equipped with unicorn
sewing machines. And this department consists of 180 operators. An interesting thing
in this department is there are contrat operators whom are so experienced on sari an
coats the payment system for those operators is peace rate system (98 birr per
coat).there are line supervisors they check qualities in each line.

Major activities in sewing department

o Making garment parts

o Sewing full garments
o Making garment accessories
o Checking of stitch qualities by supervisors
o Corrective work for defective garments

Operation break down

7.1 Draw backs of sewing room

 There is poor working conditions e.g. ergonomics

 Absence of natural air flow routs on building
 No more care for quality
 Some garments are not match with original pattern

ba 2006
Bahir dar university (EITEX) Prepared by: melkamu worke 4th GED
  The chairs are not flexible
 Sewn garments are stocked much time on the floor
 The layout is arranged by experience
 The bottleneck is high because of un effective line balancing
 UN convenient to transport between lines due to un appropriate lay out

8.1 Material Handling System

In Big-m material handling system that applied in the production area are mainly on storage
of cut pieces and to hold the bundles in the line when passing from operator to operator.
And also the tables for sorting finished garment before transfer to packing room. In this
factory there are 10 lines. Each line has central table for the purpose of storing cutting
piece. . In the sewing room different tables are available for different purposes. Such as
quality checkers table, ironing table, packing table, temporary thread table and etc. quality
checking tables that are placed after the trimming fabric is for checking the quality of the
garment produced in that line. After this there is ironing table for pressing the garment.
There are also tables packing at the station in order to hold garments to be packed.

9.1 Finishing department

In finishing department value addition works are performed (post production

proses).garments produced from sewing department are imputed to finishing for the purpose
ironing, buttoning, thread trimming folding and packaging.

 There are number of operators assigned for deferent purposes, 6 for ironing, 2 for
packaging 6 for trimming and 2 for folding.

Major activities in finishing department

 Buttoning (button holing)

 Thread trimming
 Ironing
 Final checking of garments after ironing

ba 2006
Bahir dar university (EITEX) Prepared by: melkamu worke 4th GED
  Folding and packaging.
 Dispatching into the ware house

10.1 Printing and embroidery department

Printing department plays a vital role by the side of cost reduction. At this time the
embroidery machines are not on work due to lack of maintenance so printing department take
a responsibility of embroidery section.

Major activates in printing department

 Order receive
 Prepare a design as customer interest
 Make the screen according to the design
 Select the colors for the print according to customer need
 Make a print on a required place(at the back and on front
pocket

Finance:-the finance department conducts like the functions of purchasing and selling. In
Bib-m apparel & garment plc. Firstly they check their stock. Materials (like fabric
accessories and some spare parts from both local and abroad customers.
Duty and responsibility of finance are:

 Budgeting cost flow

 Preparing salary
 Comparing profit with Processing custom duty, purchase, freight,
transport, transit charge, bank charge and etc.

Inputs of my host company

ba 2006
Bahir dar university (EITEX) Prepared by: melkamu worke 4th GED
 Raw materials, accessories and other input to the company
 Fabric  Powder
 Button  Oil
 Zipper  Poly bag
 Velcro  Elastic
 Plaster  Label
 Cartoon

11.1 Order trucking

First the customer contacts with the sales department and give an order then the sales
department makes an order based on customer need with cost of fabric, accessories and trims.
Then the sales give these orders for each department; for design section, for production
section, for finishing section, cutting section and fore dispatching section. then the seals
section give the order to the design section for sample making after making the sample the
design section gives the sample fore sales. Then the customer takes the sample for approval.
If the customer approves the sample they start mass production in cutting, sewing, finishing
and then dispatching.

12.1 SWOT analysis of my host company

Strength
 Strong financial ability
 Better position to meet customer
 And develop individual marketing
 It uses skilled personnel for its production process
 E.g. design
Weakness
There is no availability of advanced technology and notable so as to flexibility of the work
process and designing fashion styles
Absence of scheduling and training of employees to increase the capacity of workers
Space utilization also a big problem
Absence of safety procedure

Opportunity

ba 2006
Bahir dar university (EITEX) Prepared by: melkamu worke 4th GED
 Cheap labor force
UN exploited market and political stability of the country
Rule and regulations of the country

Threat
Competition

CHAPTER TWO

PROJECT WORK

Productivity improvement by line balancing on jacket

Abstract

Line balancing means balancing or leveling of work load through each operation in the
production line. Line balancing is to know how tasks are to be assigned to workstations, so
that the predetermined goal is to achieve minimum number of work stations and cycle time
and also maximization of the production rate are the most common goals. These particular
problems thus affect the productivity and the line efficiency as well. Throughout the study,
the aim is to improve productivity in my host company.

Introduction

This project is done on productivity improvement through line balancing in Big-m apparel
and garment in sewing department. Most of garment industry is affected by misbalancing of
line. This project mainly concerns on line balancing by different methods this are hiring of
operators and compiling operations and also calculating line balance efficiency.

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Bahir dar university (EITEX) Prepared by: melkamu worke 4th GED
 Literature review

Before directly going to productivity improvement first of all it shall be knows the essence of
the production and productivity mean.

 Definition of production and productivity :-

I. Production;-the word production is generally referred in mathematical sense such
as number of goods or services produced.

In addition to this production also defines a figure or numerical value which is indicator of
quantity produce or output from a production facility in a given time. Here keep in mind that
production is doesn’t give the idea about how much resources have been used as input to
produce that output.

II. Productivity: productivity can be defined in many ways but technically, it is

relationship between output and input.

Productivity=output/input

Where output refers to the goods produced by an enterprise and input refers to the resources
used to produce the output.

When I take a simple example inputs like man hour, machine hour, meters of fabric and
power consumption and it is better to say garment in different styles for an example of
output.

In my host company the significance of productivity is not well developed due to both
internal and external problems when we say internal problem that the problem can be
controlled by itself and external problem the problem beyond the company solving capacity.
in order to address the problem faced the factory it must be highly participate in
improvement of productivity .when increases productivity it leads to the stable business and
decreases garment production cost by assuring efficiency.

Factors affecting productivity

ba 2006
Bahir dar university (EITEX) Prepared by: melkamu worke 4th GED
  From the factors that affect productivity some of them are:-
 Labor turnover
 Absenteeism
 The method followed by them is not effective
 Machine delay
 Repair of break down
 Excess of non-productivity time
 Poor work station lay out

To address the above problems there must be apply productivity improvement tools.

 Continuous follow up of operators efficiency: - by comparing their efficiency and

actual production.
 Proper and simple line layout by placing machines and center tables in convenient
manner for an operation of a given style because it has a great benefit to reduce
material transportation.
 Good work station layout:-a minimum reach for operators to pick up and dispose
stitched garments, tools (trimmers, scissors etc.) when we set a good work station
layout we can minimize material handling time and operator fatigue.
 By using work aids (attachments, folders and binders) when we invest work aids we
can save our time and reduce operation cycle time in addition to this those work aids
are helpful for quality stitches.
 By developing both financial and in financial incentives: - financial incentives are
given to the employees from those bonus and better salaries are the prominent one.
When we come to non-financial incentives are creating conducive work environment
associated with facility and modern technologies and giving the chance forworkers to
participate in management teams.
If there structured incentive program in the factory the operators can perform at a pick
of their ability and exert maximum effort for the task allocated for them.
 By reducing non productivity or lose times:- it is a time spent on by operation without
producing a garment or not on an operation such as:- waiting for work, cutting and
printing not available for loading on time ,rework in production line and line setting.

ba 2006
Bahir dar university (EITEX) Prepared by: melkamu worke 4th GED
  By creating productive working environment :- the productivity improvement points
that can be stated for productive working environment are
 Continuous follow up of the process
 Manage the work but eliminating micro management
 Encourage and reward operators for their work
 Establish team work
 Spend less time in meeting rather than activities.

LINE BALANCING

What is line balancing?

Line balancing is the leveling of the workloads across all operations in line to reduce a
bottleneck operations .the purpose of line balancing is to reduce workloads at a bottleneck
operations and making smooth work flow in the line. When I look the processes and
operation during my study in the BIG-M there are improvement potentials when there is line
balancing improvement potential. in my opinion line balancing is a best tool for to reduce
operator’s idle time or to increase operator utilization. When I am in the company the
operators of the sewing line are sit in idle position due to availabilityof work. The main
reasons that I can raise for the misbalancing of line in this company are:-

-Variation in work content

- Operators performance level or skill gap

To sum up this discussion to meet the target production maintaining smooth workflow in the
line are my concern s in this garment factory.

Statement of the Problem

Poor line balancing affects the productivity and line efficiency. The skill gap, the number of
operator in that line is not equal, and absenteeism absence of operation brake down, poor

ba 2006
Bahir dar university (EITEX) Prepared by: melkamu worke 4th GED
 work station lay out, absent of garments SAM, absence of productive environment the the
method the follow also affects productivity. So I have to give a great attention to line
balance improvement in the sewing room on jacket style.

General objective

 The general objective of this project is improving productivity by line balancing

Specific objectives

 To balance the sewing line

 Keep in touch regular material flow
 To maximize machine and operator capacity
 To set or establish minimum process time
 To increase output at the desired time

 To reduce production cost and off time (non-production time

Scope of the Study

This this project is proposed in Big –m apparel and garment plc found in Addis Ababa
Ethiopia akaki kality sub city. The project focuses only on productivity improvement through
line balancing in the sewing room mainly focuses on:

 Comparison between before and after improvement

 Identification of bottle necks
 Stopwatch for time study

Methodology of the project

ba 2006
Bahir dar university (EITEX) Prepared by: melkamu worke 4th GED
 In order to intend this project I am using both primary and secondary data that are necessary
to the project.

Primarydata includes interviewing the workers and direct observation of the application.

Secondary data also includes written documents and from the internet.

Methods of data presentation

The methods using to present this data are tabulation, description and graphical presentation

o Pitch diagram
o tables

Data collections

1. 1. To do my project first I have to know:

 Target output =500 pieces per day
 No of operator (helper)=32
 No of machine in a line= 28 SNLS and 4 over locks
 Actual production output per day = 227
 SAM of the garment is not known
 Line balance efficiency is not known
 Operation break down is not known

2. To calculate productivity and efficiency of the garment first I know the following:

 Basic time
 Rating factor
 Allowances should be added

ba 2006
Bahir dar university (EITEX) Prepared by: melkamu worke 4th GED
  Allowance for SNLS-19%
 Allowance for 3threadOL-17%
 4thread OL19%
 5 thread OL 21%

Operation sections and operations

Sections Operations
Preparation Front ,back ,pockets, collar ,cuff,
waistband
Stitching of label Size label
Sub- assembly(front) Chest pocket( left and right)
Sub-assembly( back) Back pocket(right and left)
Assembly and final operations Upper and lower assembly
Trim Cut out losing threads
Checking of quality

Inspection

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Bahir dar university (EITEX) Prepared by: melkamu worke 4th GED
 ba 2006
Bahir dar university (EITEX) Prepared by: melkamu worke 4th GED
 ba 2006
Bahir dar university (EITEX) Prepared by: melkamu worke 4th GED
 Operation time, allowances, processes, rating and SAM

Operation Name of No of Time(sec) Allowance Rating Target/hr

number operation operators
1 Mark welt 1 28 0.19% 0.8 2.14285
pocket position
2 Fuse inter ling 1 28 0.19% 0.8 2.14285
3 Sew pocket belt 1 40 0.19% 0.75 1.5
4 Top stitch pocket 1 67 0.19% 0.70 0.8955
belt
5 Run stitch 1 69 0.19% 0.67 0.8695
pocket pouch
6 Serge pocket 1 64 0.17% 0.65 0.9375
pouch
7 Stitch down 1 39 0.19% 0.6 1.538
pocket welt
8 Shoulder attach 1 35 0.19% 0.67 1.714
9 Attach sleeve 1 50 0.19% 0.8 1.2
10 Topstitch sleeve 1 35 0.19% 0.78 1.714
11 Attach tape on 1 51 0.19% 0.75 1.176
sleeve
12 Mark chest 1 18 0.19% 0.58 3.33
pocket position
13 Attach chest 1 40 0.19% 0.78 1.5
pocket
14 Sew sleeve and 1 68 0.19% 0.67 0.9
side seam
15 Close sleeve cuff 1 32 0.19% 0.70 1.872
16 Fold sleeve cuff 1 31 0.19% 0.68 1.94
17 Attach sleeve 1 40 0.19% 0.6 1.5
cuff
18 Top stitch on 1 45 0.19% 0.65 1.5
cuffs
19 Serge facing 1 41 0.17% 0.67 1.463

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Bahir dar university (EITEX) Prepared by: melkamu worke 4th GED
 20 Attach facing 1 43 0.19% 0.58 1.4
21 Attach waist 1 45 0.19% 0.75 1.33
band
22 Top stitch waist 1 40 0.19% 0.67 1.5
band
23 Mark collar 1 20 0.19% 0.57 3
position
24 Sew collar edge 1 48 0.19% 0.70 1.28
to facing
25 Attach collar and 1 55 0.19% 0.65 1.0909
size label
26 Top stitch on 1 47 0.19% 0.64 1.3
collars
27 Attach zipper 1 100 0.19% 0.65 0.6
28 Stitch down 1 74 0.19% 0.67 0.8108
zipper
29 Cut and fold 1 16 0.19% 0.65 3.75
30 Trim loosing 1 48 0.19% 0.6 1.25
threads
31 inspection 1 45 0.19% 0.67 1.33
32 finishing 1 36 0.19% 0.67 1.7
Total 32 32 1438

3. Calculations

Operations A B C FORMULA D
Rating factor Standard rating O .time C*A/B=D B time
1 0.8 100 28 28*80/100 22.4
2 0.75 100 28 28*75/100 21
3 0.70 100 40 40*70/100 28
4 0.67 100 67 67*67/100 44.89
5 0.65 100 69 69*65/100 44.85
6 0.6 100 64 64*60/100 38.4
7 0.67 100 39 39*67/100 26.13
8 0.8 100 35 35*80/100 28
9 0.78 100 50 50*78/100 39

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Bahir dar university (EITEX) Prepared by: melkamu worke 4th GED
 10 0.75 100 35 35*75/100 26.25
11 0.58 100 51 51*58/100 29.58
12 0.78 100 18 18*78/100 14.04
13 0.67 100 40 40*67/100 26.8
14 0.70 100 68 68*70/100 47.6
15 0.68 100 32 32*68/100 21.76
16 0.6 100 31 31*60/100 18.6
17 0.65 100 40 40*65/100 26
18 0.67 100 45 45*67/100 30.15
19 0.58 100 41 41*58/100 23.78
20 0.75 100 43 43*75/100 32.25
21 0.67 100 45 45*67/100 30.15
22 0.57 100 40 40*57/100 22.8
23 0.70 100 20 20*70/100 14
24 0.65 100 48 48*65/100 31.2
25 0.64 100 47 47*64/100 30.08
26 0.65 100 55 55*65/100 35.75
27 0.67 100 100 100*67/100 67
28 0.65 100 74 74*65/100 48.1
29 0.6 100 16 16*60/100 16
30 0.67 100 48 48*67/100 48
31 0.67 100 45 45 45
32 0.65 100 36 36 36

Target output per hour=total number of operators*60/garment SAM

Line balance efficiency=total of the net time for each process/operation time of the longest
process*No of operators/100.

Calculations with the data from the table:

 Operation time of longest process

 Number of workers
 Total of the net time of each operation

SAM =basic time +allowances

Basic time=24min

Allowance =13.82

ba 2006
Bahir dar university (EITEX) Prepared by: melkamu worke 4th GED
 SAM should be indicated in mints

SAM=24+13.82=37.82min

SAM=37.82m

Pitch time=no operators/garment SAM

=32/37.82min

=0.8648 min

Data analysis

Through time study

Operation time of the current processes: before improvement

ba 2006
Bahir dar university (EITEX) Prepared by: melkamu worke 4th GED
 Operation Name of operation No of Time(sec)
number operators
1 Mark welt pocket position 1 28
2 Fuse inter ling 1 28
3 Sew pocket belt 1 40 From the
4 Top stitch pocket belt 1 67 pitch
5 Run stitch pocket pouch 1 69
6 Serge pocket pouch 1 64 diagram it is
7 Stitch down pocket welt 1 39 easy to
8 Shoulder attach 1 35
understand
9 Attach sleeve 1 50
10 Topstitch sleeve 1 35 which
11 Attach tape on sleeve 1 51 operations
12 Mark chest pocket position 1 18
are bottle
13 Attach chest pocket 1 40
14 Sew sleeve and side seam 1 68 necks and
15 Close sleeve cuff 1 32 where
16 Fold sleeve cuff 1 31
17 Attach sleeve cuff 1 40 operator’s
18 Top stitch on cuffs 1 45 full capacity
19 Serge facing 1 41 is not being
20 Attach facing 1 43
21 Attach waist band 1 45 utilized.
22 Top stitch waist band 1 40
23 Mark collar position 1 20 Line
24 Sew collar edge to facing 1 48 balance
25 Attach collar and size label 1 55
26 Top stitch on collars 1 47
27 Attach zipper 1 100
28 Stitch down zipper 1 74
29 Cut and fold 1 16
30 Trim loosing threads 1 48
31 Inspection 1 45
32 Finishing 1 36
Total 32 32 1438

efficiency=1438/100*32

1438/3200*100

Bottle neck operations in the diagram

ba 2006
Bahir dar university (EITEX) Prepared by: melkamu worke 4th GED
 o Stitch down pocket belt
o Run stitch pocket pouch
o Sew sleeve and side seam
o Attach zipper
o Stitch down zipper

The enhancement of line balance efficiency is very effective in productivity improvement

therefore it is recommended to set the improvement target of line balance efficiency.80% or
more of line balance efficiency is preferable.

The main job in line balancing is to eliminate or reduces work load at bottle neck
operations .to do that i have to know which operations are bottle neck in the line.

To represent the bottle neck operation in the line I prefer pitch diagram for each operations

45%

Balance lose ratio %

Balance lose ratio=100-line balance efficiency

100-45%=55%

Output per day=480min*32/37.82min*0.45

=183 pieces

Output per hour=No of operators*60minit/SAM

Output per hour=32*60/37.82

= 50.76 pieces

Project application

ba 2006
Bahir dar university (EITEX) Prepared by: melkamu worke 4th GED
 Table for solution

First improvement by additional workers and machines

By high ring and adding of machines on operation that are bottle necks or that has longest
cycle time. It is better method to reduce those bottle neck operations and improvement of
line balancing.

Operation Name of operation No of Time(sec)

number operators
1 Mark welt pocket position 1 28
2 Fuse inter ling 1 28
3 Sew pocket belt 1 40
4 Top stitch pocket belt 1 2 67
5 Run stitch pocket pouch 1 2 69
6 Serge pocket pouch 1 64
7 Stitch down pocket welt 1 39
8 Shoulder attach 1 35
9 Attach sleeve 1 50
10 Topstitch sleeve 1 35
11 Attach tape on sleeve 1 51
12 Mark chest pocket position 1 18
13 Attach chest pocket 1 40
14 Sew sleeve and side seam 1 2 68
15 Close sleeve cuff 1 32
16 Fold sleeve cuff 1 31
17 Attach sleeve cuff 1 40
18 Top stitch on cuffs 1 45
19 Serge facing 1 41
20 Attach facing 1 43
21 Attach waist band 1 45
22 Top stitch waist band 1 40
23 Mark collar position 1 20
24 Sew collar edge to facing 1 48
25 Attach collar and size label 1 55
26 Top stitch on collars 1 47
27 Attach zipper 1 2 100
28 Stitch down zipper 1 2 74
29 Cut and fold 1 16
30 Trim loosing threads 1 48
31 inspection 1 45
32 finishing 1 36
ba 2006
Total 32 37 1438
Bahir dar university (EITEX) Prepared by: melkamu worke 4th GED
 1. Sharing of operations where they are bottle necks and there

2. Shuffle operators

Operators that have low work content use low per former there and where work content is
higher use high performer.

3. By using work aids Work aids are playing a vital role to reduce operation cycle time
operator fatigue and assist operators in: Handling parts during sewing, positioning cutting
and despising finished tasks so those worker aids are the best tools to eliminate the bottle
neck operations in the line

4. by improving work station layout

Pitch diagram

Pitch diagram is used for line balancing in sewing or in assembly line and it used as
identification of bottle neck operations .from the pitch diagram it is easy to understand
bottleneck operations

ba 2006
Bahir dar university (EITEX) Prepared by: melkamu worke 4th GED
 180
160
140
120
100
80
60
40
20
0

The longest operation cycle is 64sec

Numbers of operators=operations=32

Line balance efficiency=1438/64*32

= 1438/2048

= 70%

Balance lose ratio=100-line balance efficiency

100-70%=30%

Output per day=480min*32/37.82min*0.7

= 285 pieces

Improvement by additional workers, machines and by compiling the operations

Operation No Operations No of Time in

operators second
3 Sew pocket belt 1 40
4 Stitch down pocket 2 67
1 Mark pocket welt position 28

ba 2006
Bahir dar university (EITEX) Prepared by: melkamu worke 4th GED
 5 Run stitch pocket pouch 2 69

2 Fuse inter lining 28

6 Serge pocket pouch 1 64
7 Stitch down pocket welt 1 39
8 Shoulder attach 1 35
9 Attach sleeve 1 50
10 Top stitch on sleeve 1 35
11 Attach tape on sleeve 1 521
13 Attach chest pocket 1 40
14 Sew sleeve & side seam 2 68
Mark pocket position 20
12
17 Attach cuffs 1 40
18 Top stitch on cuff 1 45
19 Serge facing 1 41
15 Sleeve cuff 32
20 Attaché facing 1 43
16 Fold sleeve cuff 31
21 Attach waist band 1 45
22 Top stitch on waist band 1 40
24 Sew collar edge to facing 1 48
25 Attach collar &size label 1 51
26 Top stitch on collar 1 50
27 Attach zipper 2 100
23 Mark collar position 24
29 Stitch down zipper 2 74
28 Cut and fold 16
30 Trim loose threads 1 48
31 Inspection 1 45
32 Finishing 1 36
Total 26 26 1438

ba 2006
Bahir dar university (EITEX) Prepared by: melkamu worke 4th GED
 120

100

80

60

40

20

0
3 +1 +2 6 7 8 9 1 0 11 1 3 1 2 1 7 1 8 1 5 1 6 21 22 24 25 2 6 2 3 2 8 3 0 3 1 32
4 5 + + + + +
14 1 9 20 27 29

Line balance efficiency=total net time of each process/longest time operation*No of

operators*100

1438/1664*100

86%

Actual output=480min*32/37.82min

=406pices

The longest cycle time is 64 sec as the same as improvement one, however the productivity
improves because the number of operations decrease from 32-26 by compiling the operations

Comparison of productivity between before and after

improvement of line balance.

Current state Improveme Improvement

ba 2006
Bahir dar university (EITEX) Prepared by: melkamu worke 4th GED
 nt one two
Working hour per 8 8 8
day
No of workers 32 37 26
Through put time 1438sec 1438sec 1438sec
Longest cycle time 100sec 64sec 64sec
Line balance 45% 70% 86%
efficiency
Output per day

Chapter three

Benefits of internship
By the assistance of my supervisors, and other colleagues i.e. Production head, section
heads are able to expand my theoretical knowledge accumulated during the class period in
to the real part of the production sector.

The potential benefits to me of participating in the Engineering Internship Program are

immense, and include the following:

Gain meaningful engineering experience to complement academic studies;

Develop a professional attitude that is reflected in the performance of responsibilities and
tasks, and learn about the importance of professionalism in the real world;
Gain experience from successful persons on related fields.
Obtain more interesting and satisfying knowledge because of the internship experience;
Stand out from other graduates in the eyes of employers;
Earn money while gaining valuable experience;.

Improving practical skill

ba 2006
Bahir dar university (EITEX) Prepared by: melkamu worke 4th GED
 One can easily see that most institution of our country is hardly practical.

Generally, the skill developed during the intern period include:-

Practical production procedures

Practical process controlling procedures

Interdisciplinary interaction.

Proper utilization of material, labor power and chemicals

How and when to check control parameters.

Selection of raw material for a specific product type.

What you gain in terms of upgrading your theoretical knowledge

Theoretical knowledge that I have learned before we got in to this internship program is mostly
based on scientific perspective rather than the engineering perspective. When you work along with
the theory that you have learned before, I t gives you practical knowledge, confidence, challenges,
and inspire to know more. Therefore I have learned more in terms of theory by further reading
different books like hand book of leather technician, principle of leather manufacture, possible
defects of leather. I have also developed my theoretical knowledge on the real production
procedures by reading and applying the specifications.

Improving interpersonal communication skill

Interpersonal communication skill includes message sending and receiving between two or more
individuals. This can include all aspect of communication like listening, persuading, asserting,
nonverbal communication and more. The communication skill that I developed during my internship
helped me to approach sort of people who are from different aspects disciplines and regions and it
show me the way how to approach professionals who are on the field.

The internship helps me to develop independency, confidence, hardworking, responsibility, and

transparency, truthfully and multi dimensionality in any department.

Improving team work skill

ba 2006
Bahir dar university (EITEX) Prepared by: melkamu worke 4th GED
 There are different professionals some have education background and others have life time
experience, which are engaged in production sector. every employer have their own task and
responsibility to perform accurately in order to keep the production in progress with the desired
quality at the required time.

Working in group it has more advantage than working individually such as reduction of critical
errors. To developed the habit of working in a group and my relation with others to be smooth and
keep continued, internship help me to developed some incredible characters like:-

 Show respect
 Open mindedness
 Trust
 Helping each other.

Improving leadership skill

Leadership is a critical management skill. Leadership skill is the ability to motivate a group of people
to achieve a incredible goal.

I developed my leadership skill by practicing the essential qualities that characterize a successful
leader while I was working with the section heads. Among the qualities; treating with good
approach, gaining mutual respect and understanding, to have employee trust etc.

I have realized a few important guidelines for achieving better leadership:-

 Positive attitude
 Clear instruction
 Personal contact
 Team work
 Planning
 Communication skill etc.

Work ethics

Understanding about work ethics:-

Knowing duty and responsibility like dressing proper working dress

ba 2006
Bahir dar university (EITEX) Prepared by: melkamu worke 4th GED
 Being punctual

Economical utilization of materials, chemicals

Use safety guard at dangers area like fleshing shaving, buffing, etc.

Have good relationship with co workers

Accepting fault

Be co operative

Being effective in performance

Share knowledge

Solve problems by discussion

Be fast to understand changes

Don’t do things by guess in order to avoid damages and wastage

Be fair to all etc

Entrepreneurship
My internship program held for four month creates the chance to meet a lot of different
entrepreneurs.

Entrepreneur is someone who searches for changes, responds to it, exploits it as an opportunity and
is a risk taker.

Internship help me developed some of the elements of entrepreneur such as:-

Being visionary and goal oriented

Risk taking

Capable of organizing skill

Self-disciplined

Strongly motivated and achievement oriented

Planner and implementer

ba 2006
Bahir dar university (EITEX) Prepared by: melkamu worke 4th GED
 Generally entrepreneur decide on the product acquire facility, and brings together the labor force,
capital, and production material.

Work ethics

Understanding about work ethics

Knowing duty and responsibility like dressing proper working dress

Being punctual

Economical utilization of materials, chemicals

Use safety guard at dangers area like fleshing shaving, buffing, etc.

Have good relationship with co workers

Accepting fault

Be co operative

Being effective in performance

Share knowledge

Solve problems by discussion

Be fast to understand changes

Don’t do things by guess in order to avoid damages and wastage

Be fair to all etc

Entrepreneurship
My internship program held for four month creates the chance to meet a lot of different
entrepreneurs.

Entrepreneur is someone who searches for changes, responds to it, exploits it as an opportunity and
is a risk taker.

Internship help me developed some of the elements of entrepreneur such as:-

Being visionary and goal oriented

Risk taking

Capable of organizing skill

ba 2006
Bahir dar university (EITEX) Prepared by: melkamu worke 4th GED
 Self-disciplined

Strongly motivated and achievement oriented

Planner and implementer

Generally entrepreneur decide on the product acquire facility, and brings together the labor force,
capital, and production material.

Conclusion

Productivity is great concern for once garment factory .to improve productivity line
balancing is a preferable tool. And also I conclude that better line balancing is important to
overcome the problems that hinders in the sewing floor

Generally I conclude that the existence of effective line balancing plays a vital role in for
productivity improvement in sewing line of my host company. So the implementation of this
project is gives a better out comes: smooth material flow, reducing reworks on defective
garments, reduction of non productive time and important to get full operator effort and can
able to assess full operator’s utilization.

ba 2006
Bahir dar university (EITEX) Prepared by: melkamu worke 4th GED
 Recommendation

In Big –m apparel and garment and garment plc there are problems or barriers for
productivity .The existence of those problems in the sewing floor has great impact on
productivity lose .I recommend that to overcome the problems that hinders in my host
company we should take effective and efficient counter measures based on the project. To
solve the problems that are existed in this factory I advice to use those line balance
productivity impartment method and knowing line balance efficiency to gage operator’s
efficiency and performance. And also I advice that the creating of productive environment
making operation break down, knowing garment SAM and better work station lay out are
the better tools to solve the problems in the sewing line of the company.

ba 2006
Bahir dar university (EITEX) Prepared by: melkamu worke 4th GED