Factory study


Objectives
-To help the manufacturers increase their productivity
-To suggest appropriate machines for different operations
-To reduce unproductive time from sewing section
-To identify the bottlenecks in manufacturing sections and suggest procedures to streamline production.
-To suggest better machine layouts for minimal material handling.
-To suggest appropriate material handling systems

Benefits
Bottleneck areas can be identified for improvement.
-A better method of reforming of operation can be Suggested thus decrease the actual sewing time.
-higher productivity which leads to higher output and more Profits for the same number of machines
-Actual output / Actual efficiency can be determined

Contents
Phase 1- Operation rate research
Phase 2 3’iitie study and method study
Phase 3 Analysis of the observed data
Phase 4 Implementation
Period- 3 to 4 days depending upon design


Line solution proposal


Basic details

  PRODUCT

  T-Shirt

  TARGET PRODUCTIO IN PCS

  1200 Pcs / Line

  TYPE OF MACHINES

  MANUAL

  AUTO ( PS-800 Placket )

  PRODUCTIVITY

  75

  100

  SAM IN SEC

  287

  236

  NO OF WORKSTSTIONS - SEWING

  17

  13


Machines Comparison




Machines Comparison



  DESCRIPTION

  MANUAL

  AUTO

  Total Investment

  $ 21, 800

  $ 29, 200

  Total Workstation

  17

  13

  Difference in W/s

  4 Nos

  Salary / Month

  ~ INR 13,500

  Savings / year

  4 * 13500 * 12 = INR   6,48,000 or $ 9, 257

  Extra Investment

  $21,800 - $ 29,200 = $7,400

  ROI

  7500 / 9527 = 0.8 Year