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Manpower Assessment St udy Report of Grasi m Bhi wani Text i l es Lt d, Bhi wani

Nat i onal Product i vi t y Counci l , Bangal ore



Confidential

REPORT ON


MANPOWER ASSESSMENT






At
GRASIM BHIWANI TEXTILES LIMITED
(A Subsidiary of Grasim Industries Limited)
BHIWANI 127 021













NATIONAL PRODUCTIVITY COUNCIL
(Under Ministry of Commerce & Industry, Govt. of India)
REGIONAL PROFESSIONAL MANAGEMENT GROUP
BANGALORE
Manpower Assessment St udy Report of Grasi m Bhi wani Text i l es Lt d, Bhi wani
Nat i onal Product i vi t y Counci l , Bangal ore


C O N T E N T S

Section Chapter Description Page No
Acknowledgement
Executive Summary 1
I Introduction 2
II Methodology 4
III Departmental reports
1 Elegant Spinning - Production 6
2 A Elegant Spinning Mechanical Maintenance 85
2 B Elegant Spinning Electrical Maintenance 107
3 BTM Spinning - Production 109
4 A BTM Spinning Mechanical Maintenance 181
4 B BTM Spinning Electrical Maintenance 254
5 A Fiber Dyeing 256
5 B Yarn Development 286
6 Weaving - Preparatory 295
7 Weaving - Loomshed 315
8 A Weaving Maintenance - Mechanical 334
8 B Weaving Maintenance - Electrical 341
9 Weaving QA 355
10 Checking, Mending And Finishing 362
11 Process House - Production 409
12 Process House - Maintenance 453
13 Logistics 467
14 Thermal Power Plant 502
15 Yarn Godown 528

Manpower Assessment St udy Report of Grasi m Bhi wani Text i l es Lt d, Bhi wani
Nat i onal Product i vi t y Counci l , Bangal ore

ACKNOWLEDGEMENT


We wish to place on record our sincere thanks to the
management of M/s Grasi m Bhiwani Textiles Limited, for
having given us the opportunity to conduct a study on
Manpower Assessment in their plant located at Bhiwani. In
particular, we sincerely thank Shri S. Krishnamoorthy
(President) and Shri Manmohan Singh (Unit Head) for
having entrusted the study to us.

We are grateful to Shri R. Subramaniam (VP-Operations)
for providing critical & valuable inputs during the study
and for ensuring that the study is carried out as per the
schedule.

We express our sincere thanks to Shri Arun Verma (AVP
HR & IR) and Shri Kaushal Tanwar (GM HR & IR) for
the timely coordination provided by them during the study.

We acknowledge the valuable time & effort spared and the
timely provision of the information & data, by all the
Officers and Staff of the plant during the study.

We also credit all the employees for their cooperation to the
NPC team during the study.






Bangalore M.L.Suryaprakash
27
t h
March 2012 Regional Director










Manpower Assessment St udy Report of Grasi m Bhi wani Text i l es Lt d, Bhi wani
Nat i onal Product i vi t y Counci l , Bangal ore



Executive Summary


The summary of the present and the proposed manpower for the various
departments studied is detailed in table 1. 1 below. The manpower
proposed for the current level of production is 1679 against the present
deployment of 1959.

The present and the proposed manpower numbers are basic manpower
(without inclusion of any relief off and leave).

Table 1.1
Summary of the Present and Proposed Manpower
S.No Department
Manpower (Numbers)
Present Proposed
1 ELEGANT SPINNING - PRODUCTION 281 275
2 A ELEGANT SPINNING - MECHANICAL
MAINTENANCE
31 30
2 B ELEGANT SPINNING - ELECTRICAL
MAINTENANCE
14 14
3 BTM SPINNING - PRODUCTION 393 355
4 A BTM SPINNING - MECHANICAL
MAINTENANCE
38 33
4 B BTM SPINNING - ELECTRICAL MAINTENANCE 21 21
5 A FIBER DYEING 58 46
5 B YARN DEVELOPMENT 16 16
6 WEAVING - PREPARATORY 122 91
7 WEAVING LOOMSHED 126 119
8 A WEAVING MAINTENANCE - MECHANICAL 5 6
8 B WEAVING MAINTENANCE - ELECTRICAL 18 16
9 WEAVING QA 7 7
10 CHECKING, MENDING AND FINISHING 249 184
11 PROCESS HOUSE - PRODUCTION 220 199
12 PROCESS HOUSE - MAINTENANCE 25 22
13 LOGISTICS 230 154
14 THERMAL POWER PLANT 70 69
15 YARN GODOWN 35 22

TOTAL 1959 1679


Manpower Assessment St udy Report of Grasi m Bhi wani Text i l es Lt d, Bhi wani
Nat i onal Product i vi t y Counci l , Bangal ore

Chapter I Introduction

1.1 The Adit ya Birla Group (ABG) is an Indian multinational
conglomerate corporation headquartered in Mumbai, India. It
operates in 33 count ries with more than 133, 000 employees
worldwide. The group has diversified business interests and is
dominant player in all the sectors in which it operates such as
viscose staple fibre, metals, cement, viscose filament yarn, branded
apparel, carbon black, chemicals, fertilisers, insulators, financial
services, telecom, BPO and IT services. The group is a US$
35 billion conglomerate which gets 60 % of its revenues from
outside India. The Adit ya Birla Group has been adjudged the best
employer in India and among the top 20 in Asia by the Hewitt -
Economic Times and Wall Street Journal Study 2007.

1.2 The Adit ya Birla Group is the world' s largest player in the Viscose
Staple Fiber industry. Apart from viscose staple fiber, the group
also owns acrylic fiber businesses in Egypt and Thailand, viscose
filament yarn businesses and spinning mills at several locations all
over India and South East Asia. The Adit ya Birla group is also a
major player in the branded garments market in India.

1.3 The Adit ya Birla Group wanted to improve their productivit y in
three of their textile units in India and accordingl y they have
requested National Productivit y Council (NPC) to take up the study.

1.4 M/s. Grasim Bhiwani Textiles Limited (GBTL) is a verticall y
integrated textile mill with two spinning division, one we aving
division and a fabric processing division.


1.5 Scope of Grasim Bhiwani Textiles Limited (GBTL):

1.5.1 The scope of the study includes the assessment of manpower
(workmen onl y) for operating the BTM Spinning and Elegant
Spinners having combined spindle capacit y 35, 728 nos. and
other related & support functions e.g. maintenance,
engineering and qualit y assurance.

1.5.2 The manpower assessment study shall also be conducted for
the workmen of weaving department of 140 looms and
fabric processing having capacit y of 15 lakhs meters per
month and related & support functions e. g. maintenance,
engineering and qualit y assurance.

Manpower Assessment St udy Report of Grasi m Bhi wani Text i l es Lt d, Bhi wani
Nat i onal Product i vi t y Counci l , Bangal ore

1.5.3 The study will also cover the manpower deployed in
logistics (Warehouse and Dispatch) and Yarn Godown
activities.

1.5.4 The study will be limit ed to the manpower requirement of
non-executive (workmen category) cadre employees of the
plant operation.
Manpower Assessment St udy Report of Grasi m Bhi wani Text i l es Lt d, Bhi wani
Nat i onal Product i vi t y Counci l , Bangal ore

Chapter II Methodology

2.1 The manpower assessment study was carried out by a team of
consultants of National Productivit y Council, led by the Chief
Consultant and the individual consultants drawn from the
Bangalore office and New Delhi office. NPC deputed a team of
four Consultants to carry out the detailed studies. The field
studies in Bhiwani were carried out from 16
t h
November 2011
till 14
t h
January 2012.

2.2 The assignment was kicked off by an opening meeting with the
unit head and the HODs of the various departments. The
methodology to be followed by the team, expectation from the
various stakeholders and the various time lines were clearl y
explained in the meeting. This was followed by a plant visit and
initial discussions amongst the team members. The following
steps were followed for the detailed studies in the concerned
areas.

2.3 The manpower requirement of Permanent and Contract
employees (other than maintenance) was determined by the
following process

2.3.1 Collection of the data regarding the activities, frequencies,
machine characteristics, for all the personnel involved in all the
departments.

2.3.2 NPC consultants conduct ed detailed time and moti on studies for
all the jobs involving both the categories of workmen.

2.3.3 NPC also collect ed the requisite clarifications regarding the
activities carried out, frequency of occurrence and records
maintained through discussions with the employees, direct
observation and also through perusal of past records and
documents.

2.3.4 The rest and relaxation allowances were computed based on
ILO recommendations and NPC' s own experience in this area.

2.3.5 The manpower was rationalized through reallocation of duties /
tasks to even out the variations in work loads, if required.
Manpower Assessment St udy Report of Grasi m Bhi wani Text i l es Lt d, Bhi wani
Nat i onal Product i vi t y Counci l , Bangal ore

2.4 The manpower requirement of Permanent and Contract
employees in the maintenance departments was determined
by the following process

2.4.1 Collection of the data regarding the activities, frequencies, and
crew deployed for the breakdown maintenance and preventive
activities. NPC consultants conducted the time and motion
studies on a sample basis for the maintenance activities and the
observations made were applied to the preventive and
breakdown maintenance activities.

2.4.2 Appropriate rest and relaxation allowances were computed
based on ILO recommendations and NPC' s own experience in
this area and applied to the various works.

2.4.3 For the general shift personnel who are predominantl y
performing preventive maintenance works and major breakdown
maintenance works, the manpower has been calculated for 80 %
loading. The rationale is explained in the individual
departmental sheet s.

2.4.4 Work sampling studies were carried out during the shift for the
crew to determine the utilization of the personnel in the various
activities, wherever required.

2.5 The report was submitted to the GBTL management on 20
t h

February 2012. Detailed discussions were conducted with the
management team of the GBTL which comprised of AVP
(Operations), AVP (HR & IR) and the concerned HOD and a
presentation was performed to the President. Based on the
inputs provided during the discussions, appropriate changes
were made in the manpower deployment and the finalized
manpower deployment is presented in t his report.














Manpower Assessment St udy Report of Grasi m Bhi wani Text i l es Lt d, Bhi wani
Nat i onal Product i vi t y Counci l , Bangal ore






















________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
1.0 ELEGANT SPINNING - PRODUCTION
________________________________________________________________________________________
National Productivity Council, Bangalore.
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___________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
1.0
1.1
I II III G T I II III G T
1 Mixing Mixing man 7 7 7 - 21 6 6 6 - 18
Waste Sorter - - - 3 3 - - - 3 3
2 Blow Room Tenter 3 3 3 - 9 3 3 3 - 9
3 Carding. Tenter 3 3 3 - 9 3 3 3 - 9
4 Draw Frame Sider 2 2 2 - 6 2 2 2 - 6
5 Speed Frame Sider 3 3 3 - 9 3 3 3 - 9
Doffer 2 2 2 - 6 2 2 2 - 6
Jobber 1 1 1 - 3 1 1 1 - 3
Jam Cutter - - - 1 1 - - - 1 1
6 Ring Frame Sider 9 9 9 - 27 9 9 9 - 27
Doffer 16 16 16 - 48 16 16 16 - 48
Doffer-Reliever 2 2 2 - 6 2 2 2 - 6
Jobber 1 1 1 - 3 1 1 1 - 3
Seggerator 1 1 1 - 3 1 1 1 - 3
Checker 1 1 1 - 3 1 1 1 - 3
ELEGANT SPINNING - PRODUCTION
Manpower Deployment *
S. No Section / Work area Designation
Present Manpower Proposed Manpower
Remarks
_________________________________________________________________________________________________________________________________
National Productivity Council, Bangalore.
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___________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
1.0
1.1
I II III G T I II III G T
ELEGANT SPINNING - PRODUCTION
Manpower Deployment *
S. No Section / Work area Designation
Present Manpower Proposed Manpower
Remarks
Floor Cleanner 1 1 1 - 3 1 1 1 - 3
7 Autoconer Jobber 1 1 1 - 3 1 1 1 - 3
Checker 1 1 1 - 3 1 1 1 - 3
Winder 7 7 7 - 21 7 7 7 - 21
Winder -Reliever 1 1 1 - 3 1 1 1 - 3
Doffer 1 1 1 - 3 1 1 1 - 3
Bobbin Sorter 2 2 2 - 6 2 2 2 - 6
Floor Cleaner 1 1 1 - 3 1 1 1 - 3
8 Cheese Winding Winder-RJK 4 4 4 - 12 4 4 4 - 12
Winder-SSM 2 2 2 - 6 2 2 2 - 6
Winder-Reliever 1 1 1 - 3 1 1 1 3
Cone
winding(Rewinding
)
- - - 1 1 - - - 1 1
9 Two-for-one(TFO) Jobber 1 1 1 - 3 1 1 1 - 3
Doff Carrier 1 1 1 - 3 1 1 1 - 3
Tenter 8 8 8 - 24 8 8 8 - 24
_________________________________________________________________________________________________________________________________
National Productivity Council, Bangalore.
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___________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
1.0
1.1
I II III G T I II III G T
ELEGANT SPINNING - PRODUCTION
Manpower Deployment *
S. No Section / Work area Designation
Present Manpower Proposed Manpower
Remarks
Tenter-Reliever 1 1 1 - 3 1 1 1 - 3
Floor Cleaner 1 1 1 - 3 1 1 1 - 3
Sweeper - - - 1 1 - - - 1 1
10 Packing Checker - - - 3 3 - - - 3 3
Lot-Final Checker - - - 1 1 - - - 1 1
Packer - - - 6 6 - - - 4 4
11 Cone-Tipping - - - 1 1 - - - 1 1
12 Yarn Conditioning - - - 2 2 - - - 1 1
13 Quality Assurance
Investigator 1
- - - 1 - - - 1 1
Checker 2 2 1 1 6 2 2 1 1 6
88 87 86 20 281 86 86 85 18 275
* The above manpower deployment table is for 30s Count.
Total
_________________________________________________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
1.0
1.2
1.2.1
I
a)
b)
c)
d)
P
r
o
d
u
c
t
i
o
n

(
k
g
s
)

/
H
o
u
r
P
a
r
a
m
e
t
e
r
s
21
14.6
148
320
115.5
120
spindle/
machine
CARDING-LR
D/F Breaker
15 Kg/ Can
D/F Finisher
Speed frame
ELEGANT SPINNING - PRODUCTION
Proposed Changes & Observations
I
n
p
u
t

p
e
r

s
h
i
f
t

p
e
r

m
a
c
h
i
n
e
O
u
t
p
u
t

Q
u
a
n
t
i
t
i
e
s
Methodology
15 Kg/Can
4.80 35 Kg/ Can 12.92
The machine efficiency and operator workload are depicted in the graph to findout the
optimum (where running efficiency & operative workload meets) number of machines to be
alloted per personnel.
It is assumed that machines are subject to stops at random and unpredictable intervals. It is
also assumed that the operator will service a machine with the minimum delay after the
machine has stopped, and that if two or more are stopped at one time,he will attend to them
by taking the nearest first. This method of servicing is called random tending. Thomas F.O'
Connor, provided the table for calculating the machine efficiency and operators workload in
this type of multimachine assignment problem in the book: Efficiency and Productivity
Tables for Textile Machine Operation, Institute of Textile Technology,Virginia.
CARDING-
CROSSROL
170.67
462.00
15 kg/Can
2 Kg/ Roving
7.79
61.60
78.93
170.67
Carding,Drawframe and Speedframe
8.98
33.83
o
u
t
p
u
t

p
e
r

s
h
i
f
t

p
e
r

m
a
c
h
i
n
e
The frequency values are taken from the following tables for the repsective sections:
M
/
C

N
a
m
e
In Carding, Drawframe and Speed frame sections, the operator is responsible for the
operation of more than one machine, if two machines stop at a time and require tenter's
attention simultaneously,one of the machine must wait until he completes his work on the
other. This time loss representing waiting time due to overlapping of machine stoppage is
called "Interference loss".
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
1.0
1.2
ELEGANT SPINNING - PRODUCTION
Proposed Changes & Observations
1.2.1
II
a)
b)
c)
d)
e)
f)
r = (b-1) / [ gN{K+(b-1)C}]
The running efficiency is arrived by the following formula provided by the research paper.
The working pattern of operators in Ringframe, Autconer, Cheese winding and Two-for-
One(TFO) is entirely different from the preceding section.In this areas,the operator's services
the machine in a cyclical manner and attends to each machines(drums) as he comes to it.
The difficulty in dealing with these problems lies in calculating the effect of "interference"
which is the term used for incidence of simultaneous stoppages at several machines. In fact, if
the optimum number of machines is being controlled by one operative, the machine efficiency
required will be a marked feature.
The research paper "The Efficiency of N machines Uni-Directionally patrolled by
single operative" by Mr.C.Mack,T.Murphy and N.L.Webb,Journal of the Royal
Statistical Society, (1957), has been used to arrive the machines running efficiency for the
different number of machines handled by the operators in the above sections considering the
following working methodology:
Ringframe, Autoconer, Cheesewinding and Two-for-One(TFO)
r = Running Efficiency, i.e the percentage of running time to total (stopped + running)
time.Stopped means time lost due to interference and breaks includes rectification of
breaks.
C - Time to repair and restart the machine
The operative walks round the machines in a defined order and repairs and restarts any
machine which is found stopped, passing after inspecting and/or servicing any machine
which is running. It is assumed that the machine stops at random with the same mean
frequency and independent of each other.
g - Random breakdowns in running time @ each machine/drum
N - Number of machines
K- Mean walking time from one machine to next machine, includes inspection time
b = exp(gNK)
The operator workload is calculated by multiplying the time taken for different activities to be
performed with the frequency of the activities for the allotted number of machines.
Methodology
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
1.0
1.2
ELEGANT SPINNING - PRODUCTION
Proposed Changes & Observations
1.2.1
g)
h)
M
/
C

N
a
m
e
P
r
o
d
u
c
t
i
o
n

(
K
g
s
)
/

H
o
u
r
M
a
c
h
i
n
e

P
a
r
a
m
e
t
e
r
s
O
u
t
p
u
t
A
v
a
i
l
a
b
l
e

h
o
u
r
s
/

S
h
i
f
t
M
/
C

a
v
a
i
l
a
b
l
i
t
y

l
o
s
t

%

M
/
C

A
v
a
i
l
a
b
i
l
i
t
y

(
%
)
T
o
t
a
l

T
i
m
e

a
v
a
i
l
a
b
l
e

f
o
r

p
r
o
d
u
c
t
i
o
n
/
S
h
i
f
t
I
n
p
u
t

p
e
r

s
h
i
f
t

(
o
f

r
e
s
p

e
f
f
i
c
i
e
n
c
y
)

p
e
r

m
/
c
o
u
t
p
u
t

p
e
r

s
h
i
f
t

(
o
f

r
e
s
p

e
f
f
i
c
i
e
n
c
y
)

p
e
r

m
/
c
R/F 16.95
576
spindle/m
achine
60 gms
Bobbin
8 8 92% 7.36 62.38 2079.20
Autoco
ner-
Murate
ch
77.5
60
spindle/m
achine
2 Kg
Cone
8 30 70% 5.6 7233.33 217.00
Autoco
ner-
Savio
77.5
60
spindle/m
achine
2 Kg
Cone
8 25 75% 6 7750.00 232.50
Cheese
Windin
g-RJK
150
160
spindle/m
achine
1 Kg
Cheese
8 28 70% 5.6 420.00 840.00
TFO 10.2
156
spindle/m
achine
2 Kg
Cone
8 2.5 97.5% 7.8 79.56 39.78
1.2.2
I
a)
The frequency values are taken from the following tables for the repsective sections:
Proposed Changes
Mixing Blenders:
In view of low utilisation (69.44 %), it is recommended to deploy six personnel instead of the
present seven personnel in a shift for three mixing blenders operation. The proposed
utilisation of six personnel would be 81.01%
The running efficiency values and operator workload are depicted in the graph to findout the
optimum (where running efficiency & operative workload meets) number of drums to be
alloted per personnel.
Methodology
________________________________________________________________________________________
National Productivity Council, Bangalore.
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1.0
1.2
ELEGANT SPINNING - PRODUCTION
Proposed Changes & Observations
1.2.2
II
a)
III
a)
b)
IV
a)
1.2.3
I
a)
Yarn Conditioning Room
In view of low utilsation 39.77 % of two personnel,it is recommended to deploy one person in
the yarn conditioning operation.The proposed utilisation of the personnel would be 79.55%
Carding
It was observed that the carding tenter, dump the different coloured sliver waste collected
together in a single place near the machine. Say for example, brown colur with the black
colour waste. Hence,the waste is again to be segregated by waste sorter. It is recommended
that the tenter's should not mix the waste and advice to dump different coloured waste
separately.
Observations
Deploy four personnel as the packer instead of present six personnel. The proposed utilisation
of the group is 72.33 %.
Keeping in mind,the number of trolley and weighing machine,space constraint on the
packing table,and in order to prevent mixing, four personnel is recommended.
Packing - Packers
Carding Tenter:
Deploy two operator for carding machine operation and deployment as follows:
one operator - 12 crossrol machine
Second operator- 6 LR + 4 Crossrol machines.
The third operator is provided as the reliever for carding tenters(2 personnel),Drawframe
tenter(2 nos). Presently drawframe tenter is being relieved by jobber.
Proposed Changes
________________________________________________________________________________________
National Productivity Council, Bangalore.
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1.0
1.2
ELEGANT SPINNING - PRODUCTION
Proposed Changes & Observations
1.2.3
II
a)
III
a)
Observations
The machine gets stopped because of lack of coloured cans. Bands are used presently to
differentiate count/colur. It was observed that there is no fixed standard for this.Hence, there
would be a chance of mixing. It is suggested to makke visual display of the colour
combinations(can colour+band colour) and their repsective count. Presentlyas there is no
proper visual board or colour standards,operators are waiting for the checker/jobber's help in
changing or using the cans.
Effective Co-ordination- Ringframe Doffers
Drawframe
From the field study, it has been observed that the time taken for count change in ringframe
section purely depends on the people management skill level of doffer leader. During the day
of study, it was observed that because poor planning, the ringframe was stopped more than
two-three hours for count change In the middle, they have taken another machine for ring
travellours change. It affects the machine availability time for the production.
________________________________________________________________________________________
National Productivity Council, Bangalore.
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1.0
1.3
S.No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
Mixing Man ESP/W/01
ELEGANT SPINNING - PRODUCTION
Workload Sheets Summary
Area of work WLS Number
Carding Tenter ESP/W/05 & A
Cheesewinding-Winder(RJK) ESP/W/27
Blowroom Tenter-1&2 ESP/W/03
Blowroom Tenter-3 ESP/W/04
Cheesewinding-Winder(SSM) ESP/W/26
Drawframe -Sider ESP/W/06
Speedframe Tenter ESP/W/07
Speedframe Doffer ESP/W/08
Speedframe Jobber ESP/W/09
ESP/W/10 Speedframe-Jam cutter
Packing -Packer ESP/W/38
Autoconer-Winder ESP/W/21 & A
Autoconer-Doffer ESP/W/23
QA-Checker ESP/W/42
QA- Investigator ESP/W/41
Cheesewinding-Winder Reliever ESP/W/28
TFO- Tenter Reliever ESP/W/33
Cheesewinding-Rewinding ESP/W/29
Cone tipping ESP/W/39
Yarn conditioning Room ESP/W/40
Autoconer-Bobbin Sorter ESP/W/24
Autoconer-Floor Cleaner ESP/W/25
Packing - Checker ESP/W/36
Autoconer-Jobber ESP/W/19
Packing -Lot Final Checker ESP/W/37
Ringframe-Checker ESP/W/17
Ringframe-Floor cleaner ESP/W/18
TFO- Tenter ESP/W/32
Ringframe-Sider ESP/W/11
Ringframe-Doffer ESP/W/12
Ringframe-Jobber ESP/W/15
Ringframe-Doffer Reliever ESP/W/14
Ringframe-Doffer Leader ESP/W/13
Waste Sorter ESP/W/02 & A
TFO- Jobber ESP/W/30
TFO- Doff Carrier ESP/W/31
Ringframe-Segregator ESP/W/16
Autoconer-Checker ESP/W/20
TFO- Sweeper ESP/W/35
TFO- Floor Cleaner ESP/W/34
Autoconer-Winder Reliever ESP/W/22
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 7 7 7 -
Designation Proposed Manpower 6 6 6 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
a 1 1 4.95 4.95
b 1 1 2.48 2.48
c 2 1 10.50 21.01
d 1 1 4.00 4.00
e 1 1 1.13 1.13
2
a 2 5 3.92 39.15
b 1 5 1.42 7.11
c 1 2275 0.026 59.32
d 1 2275 0.028 62.73
e 1 20 3.85 77.00
a 2 3 3.92 23.49
f 1 3 1.42 4.26
g 1 1225 0.026 31.95
h 1 1225 0.028 33.78
i 1 3500 0.08 280.00
3
a
b
4
a
b
385 3500 0.11
1 3500 0.11 385
Cut the material vertically in the mixing bin,lift and feed
on blender belt conveyor
WLS No: ESP/W/01
WORK LOAD DETAILS SHEET
Elegant Spinning
Shifts A B C G
Mixing Room
Bring the chemical ( AS 400) from the plastic drum in
the presence of supervisor after weighing
Bring the chemical ( AS 200) from the plastic drum in
the presence of supervisor after weighing
Bring the hot water in a plastic drum from geyser
Blender
Mixing Boy
Activity Description
Spin Finish Solution preparation ( No 1 & 3)(in front
of shift incharge)
Do layering by spreading polyester and viscose on the
alternate layer by manually
Mix the AS-200 & AS-400 one by one in the hot water
Bring the polyester bags from respective area to near the
machine
Layering
Open the bales of polyester bags
Bring the viscose bags from respective area to near the
machine
Take the polyester from bags and put it on the belt
conveyor(feed end)
Open the bales of viscose bags
Take the viscose from bags and put it on the belt
conveyor(feed end)
To pickup the viscose from beater & spread in mixing
Spread the blender output (inside the bin) evenly by
manual
Second Toppling (Mixing)
Cut the material vertically in the mixing bin,lift and feed
on blender belt conveyor
Spread the blender output (inside the bin) evenly by
manual
1
Keep the empty chemical cans in the respective area
Spray the spin finish solution uniformly on the every
layer of polyester fibre using spray pump
Spread the blender output (inside the bin) evenly by
manual
First Toppling (Mixing)
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 7 7 7 -
Designation Proposed Manpower 6 6 6 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
WLS No: ESP/W/01
WORK LOAD DETAILS SHEET
Elegant Spinning
Shifts A B C G
Mixing Room
Blender
Mixing Boy
Activity Description
5
a
b
6
a
b
c
d
A 1869.52
B 17
C 2187.34
D 450
E 69.44%
F 6
G 81.01%
1 3500 0.11 385
Proposed Utilisation(%)
Target - 2500 Kg /person * 7 persons / shift =17500 kg / shift . Each batch have 5 steps. It
becomes 3500 kg batch ( 3500 * 5 steps = 17500 kg)
P/V (65/35) mixing is considered. Hence , 3500 *65% Polyester = 2275 kg / shift , 3500 * 35%
Viscose =1225 kg/ shift.
As minimum two personnel required per mixing room, six personnel is being recommended per
shift for three blowrooms.
Lot Change ( Shade Change)
Clean the bins before starting the mixing.
Final Toppling (Mixing)
Rest & Relaxation Allowances ( % )
1 1 62.17
Basic Workload per Shift ( in man minutes)
Clean the blender & beater
Clean the floor area around the machine
To remove the jam of beater & blender ( if any)
Spread the blender output (inside the bin) evenly by
manual
Cut the material vertically in the mixing bin,lift and feed
on blender belt conveyor
62
Remarks:
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 1
Designation Proposed Manpower - - - 1
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 20 101.00 101.00
2 1 20 9.40 9.40
3 1 2 38.00 38.00
4 1 4 48.00 48.00
5
1 1 25.00 25.00
A 221.40
B 13
C 250.18
D 480
E 52.12%
F 1
G 52.12%
WLS No: ESP/W/02
WORK LOAD DETAILS SHEET
ELEGANT
Shifts A B C G
PREPARATORY
Basic Workload per Shift ( in man minutes)
MIXING
WASTE
SORTER/CARRIER
Activity Description
Putting waste from carding m/c into bags & weighing
Sewing the bags
Cleaning the area
Bring material from store(antistatic, stationery etc.)
Deliver waste report to post spinning and then to raw
material dept.
Proposed Utilisation(%)
Remarks:
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 2
Designation Proposed Manpower - - - 2
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
2 238.64 477.29
2 2 26.57 53.14
3 2 4 42.40 84.80
4
2 20 bags 22.00 44.00
A 659.23
B 13
C 744.93
D 480
E 77.60%
F 2
G 77.60%
G
PREPARATORY
Cleaning the whole area with broom
Helping in weighing of bags
WLS No: ESP/W/02 A
WORK LOAD DETAILS SHEET
ELEGANT
Shifts A B C
MIXING
WASTE SORTER
Activity Description
Waste sorting-Avg. waste coming in
=294.57KG/shift 120 KG
Placing the sorted out material in respective bags
Basic Workload per Shift ( in man minutes)
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Remarks:
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 2 2 -
Designation Proposed Manpower 2 2 -
Sl.
No
Cre
w
Size
Freq/
machi
ne /
Shift
No of
machi
nes
Basic
Time
(Mins)
Total
Time
(Mins)
1
1.1 1 1 2 2.00 4.00
1.2 1 1 2 5.00 10.00
2 1 1002 2 0.073 146.29
3 1 78 2 0.23 35.88
4 1 78 2 0.15 22.78
5
1 78 2 0.13 20.59
6 1 76 2 0.36 54.26
7 1 76 2 0.15 22.34
8
1 78 2 0.21 32.45
9 1 1 2 2.00 4.00
10 1 1 2 2.31 4.62
11 1 2 2 4.00 16.00
12 1 0.44 2 90.00 79.20
13 1 1 2 4.00 8.00
A 460.42
B 15
C 529.48
D 450
E 58.83%
F 2
G 58.83%
Lot change - 4 machine/(3 shifts*3 machine) = 0.44 /shift/machine
Machine Capacity - 155 kg/ hour * 8 hour * 80% machine availability= 992 kg /13 kg lap = 77
laps
Rejection (0.01%) = 992*0.01 = 9.92 kg/13kg lap= 1 lap
Total Workload ( in man minutes )
Net Available man-mins
Rest & Relaxation Allowances ( % )
Basic Workload per Shift ( in man minutes)
Total =992 kg+9.92 kg = 1002 kg
C
2
2
Enter the lap weight and number in the Lap
production Register
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Remarks:
Keep the lap rod in the machine for new lap
At the shift end weigh the waste collected in the
carding section and collect it.
Break rejected laps into small tufts and feed them
Clean the machine and area around the machine at
the shift end and at intervals.
Clean the machine during lot change
Remove the lap rod from the machine and keep on
the weighing machine and ensure that lap weight is
under tolerance limit. +/-200 gms
Take the polycover and tie on the lap
Keep the lap in the respective zone
To adject the lap weight if found above the limits
Bring the materials from mixing bin room (vertical
cut) & feed on the machine lattice
Keep the spindle on machine stand for next lap
Blowroom-1&2
Tenter
Activity Description
Shift Changeover activities
Check the machine parameters like length
counter,count,batch,shade no etc
To counter check weight of 5 laps of out going shift.
WLS No: ESP/W/03
WORK LOAD DETAILS SHEET
Elegant Spinning
Shifts A B G
Blowroom
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 1 1 1 -
Designation Proposed Manpower 1 1 1 -
Sl.
No
Crew
Size
Freq/
machi
ne /
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
1.1 1 1 2.00 2.00
1.2 1 1 5.00 5.00
2 1 1002 0.073 73.15
3 1 78 0.15 11.39
4
1 78 0.13 10.30
5 1 77 0.36 27.49
6 1 77 0.15 11.32
7
1 78 0.21 16.22
8
1 1 2.00 2.00
9 1 1 2.31 2.31
10 1 2 4.00 8.00
11
1 0.44 90.00 39.60
12
1 1 4.00 4.00
13
14
A 212.77
B 15
C 244.69
D 450
E 54.38%
F 1
G 54.38%
Rejection (0.01%) = 992*0.01 = 9.92 kg/13kg lap= 1 lap
Total =992 kg+9.92 kg = 1002 kg
Lot change - 4 machine/(3 shifts*3 machine) = 0.44 /shift/machine
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Remarks:
Target per shift /tenter - 992 kg/13 kg lap = 77 laps
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Clean the machine during lot change
At the shift end weigh the waste collected in the carding
section and collect it.
Stop the machine and check when alarm arised
To inform the fitter/ electrician/supervisor if any
abnormalities found.
Enter the lap weight and number in the Lap production
Register
To adjust the lap weight if found above the limits
Break rejected laps into small tufts and feed them equally
Clean the machine and area around the machine at the
shift end and at intervals.
Keep the lap in the respective zone
Blowroom-3
Tenter
Activity Description
Shift Changeover activites
Check the machine parameters like length
WLS No: ESP/W/04
WORK LOAD DETAILS SHEET
Elegant Spinning
Shifts A B C G
Blowroom
Bring the materials from mixing bin room (vertical cut)&
feed on the machine latice
Keep the lap rod in the machine for new lap
Remove the laprod from the machine and keep on the
weighing machine and ensure that lap weight is under
tolerance limit. +/-200 gms
Take the polycover and tie on the lap
To counter check weight of 5 laps of out going shift.
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 3 -
Designation Proposed Manpower 3 -
Sl.
No
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1
t2 1 8 1.00 13 9.04
2
t2 12.92 8 0.24 16 28.93
3 t2 12.92 8 0.31 13 35.87
4
t2 12.92 8 0.44 15 52.66
5
t2 12.92 8 0.21 14 24.76
6
t2 1.84571 8 0.90 14 15.20
7
t2 1.84571 8 0.85 15 14.47
8
t2 1.84571 8 0.79 15 13.40
9
t2 1.84571 8 0.18 13 3.00
11
t2 4.8 8 0.63 13 27.34
12
t2 4.8 8 0.35 13 15.01
13 t 0.144 8 2.00 13 2.60
10
t1 2 2 4.36 13 19.71
14 t2 4 1 1.74 13 7.86
15
t2 1 8 0.50 13 4.52
16
t2 4 1 3.52 13 15.92
17
t1 1 1 0.60 13 0.68
18
t1 1 1 1.02 13 1.15
B C
3 3
WLS No: ESP/W/05
Elegant
Spinning
Shifts G
Spinning
WORK LOAD DETAILS SHEET
A
Bring the trolley with laps back to carding
section
Return back the lap rod and cover to blow
room section
Bring the empty can and keep on the
machine
Carding
Tenter
Activity Description
Reset the machine parameter at the shift
starting
Load new lap rod on the machine stand
from trolley/floor
Remove the lap cover from the lap
Feed the lap on the machine (from machine
stand to roller)
Remove the empty lap rod from the
machine & place on the trolley
Move the empty trolley to blow room from
carding section
Load the new laps from blow room section
on the trolley (7 laps per trolley)
Move the filled can from the machine and
keep in the respective area
Attend the sliver cut problem
Check the suction hood working condition
Clean the bruce wheel at the shift end and
collect the waste
Move the waste collected to blow room
section yellow bag
Remove the suction hood waste (in the
blow room)
Bring the yellow bag from blow room
section
Clean the work area around the machines
3 3
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 3 -
Designation Proposed Manpower 3 -
Sl.
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B C
3 3
WLS No: ESP/W/05
Elegant
Spinning
Shifts G
Spinning
WORK LOAD DETAILS SHEET
A
Carding
Tenter
Activity Description
3 3
19
t1 1 1 4.10 13 4.64
20
t 0.06 8 15.00 13 8.54
Clean the machine at the time of lot change
Thomas O Connor table
8 94.36% 60.02%
T (M/C running time per cycle) = 480 mins per shift *8 machines = 3840 mins
The above values are depicted in the graph to find out the optimum (where running efficiency
& operative workload meets) number of drums to be allotted per personnel and presented
below:
Hand over the waste collected in the
carding section after weighment at the shift
end
11
93.13%
90.16% 78.85%
91.74% 10
12 88.38%
t1(Average time in min taken by operator per mrh to perform necessary deferrable work
while m/c is running) = 26.18 mins
t2 (Average time in min taken by operator per mrh to perform non-deferrable work while m/c
is running ) = 267.98 mins
t (Average time in min taken by operator per mrh to perform non-deferrable work with the
machine stopped) = 11.15 mins
No of Machines Machine Efficiency(%) Operator workload(%)
9
84.32%
14 84.17% 93.68%
The machine efficiency and respective operative workload for the values above is found out
from the Thomas O' Connar table and tabulated below:
66.64%
72.94%
13 86.38% 89.28%
15 81.75% 97.50%
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 3 -
Designation Proposed Manpower 3 -
Sl.
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B C
3 3
WLS No: ESP/W/05
Elegant
Spinning
Shifts G
Spinning
WORK LOAD DETAILS SHEET
A
Carding
Tenter
Activity Description
3 3
Lot change - 4 machine/(3 shifts*22 machines) = 0.06 /shift
From the graph, the optimum number of machine can be allotted per operator is 12 nos.
Remarks:
Two operator and one common reliever for Blowroom and carding
8 9 10 11 12 13 14
Machine Efficiency(%) 94.36% 93.13% 91.74% 90.16% 88.38% 86.38% 84.17%
Operator Workload(%) 60.02% 66.64% 72.94% 78.85% 84.32% 89.28% 93.68%
0.00%
10.00%
20.00%
30.00%
40.00%
50.00%
60.00%
70.00%
80.00%
90.00%
100.00%
E
f
f
i
c
i
e
n
c
y
(
%
)
Carding-Crossrol
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower -
Designation Proposed Manpower -
Sl.
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1
t2 1 7 1.00 13 7.91
2
t2 12.92 4 0.24 16 14.46
3 t2 12.92 4 0.31 13 17.93
4
t2 12.92 4 0.44 15 26.33
5
t2 12.92 4 0.21 14 12.38
6
t2 1.84571 4 0.90 14 7.60
7
t2 1.84571 4 0.85 15 7.23
8
t2 1.84571 4 0.79 15 6.70
9
t2 1.84571 4 0.18 13 1.50
10
t2 4.8 4 0.63 13 13.67
11
t2 4.8 4 0.35 13 7.51
12 t 0.144 4 1.20 13 0.78
13
t2 8.98 3 0.24 16 7.54
14 t2 8.98 3 0.31 13 9.35
15
t2 8.98 3 0.44 15 13.73
16
t2 8.98 3 0.21 14 6.45
17
t2 1.28286 3 0.90 14 3.96
Carding
WLS No: ESP/W/05 A
Elegant
Spinning Shifts B G
Spinning
A
WORK LOAD DETAILS SHEET
Load the new laps from blow room section
on the trolley (7 laps per trolley)
Bring the trolley (with laps) back to carding
section
Return back the lap rod and cover to blow
room section
Activity Description
Reset the machine parameter at the shift
starting
Load new lap rod on the machine stand
from trolley/floor
Remove the lap cover from the lap
Crossrol
Move the empty trolley to blow room from
carding section
Remove the empty lap rod from the machine
& place on the trolley
Move the empty trolley to blow room from
carding section
Feed the lap on the machine (from machine
stand to roller)
Tenter
Bring the empty can and keep on the
machine
Move the filled can from the machine and
keep in the respective area
Attend the sliver cut problem
Feed the lap on the machine (from machine
stand to roller)
Remove the empty lap rod from the machine
& place on the trolley
LR
Load new lap rod on the machine stand
from trolley/floor
Remove the lap cover from the lap
C
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower -
Designation Proposed Manpower -
Sl.
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Carding
WLS No: ESP/W/05 A
Elegant
Spinning Shifts B G
Spinning
A
WORK LOAD DETAILS SHEET
Activity Description
Tenter
C
18
t2 1.28286 3 0.85 15 3.77
19
t2 1.28286 3 0.79 15 3.49
20
t2 1.28286 3 0.18 13 0.78
21
t2 7.79 3 0.63 13 16.64
22
t2 7.79 3 0.35 13 9.14
23 t 0.2337 3 1.15 13 0.91
24
t1 4 3 1.06 13 14.37
25 t2 2 3 1.50 13 10.17
26
t1 4 3 1.61 13 21.87
27
t1 2 3 2.49 13 16.88
28 t1 4 3 1.21 13 16.37
29
t1 2 2 4.36 13 19.71
30 t2 4 1 0.87 13 3.93
31
t2 1 4 1.02 13 4.61
32
t2 2 1 3.52 13 7.96
33 t1 1 1 0.60 13 0.68
34
t1 1 1 1.02 13 1.15
35
t1 1 1 4.10 13 4.64
Attend the sliver cut problem
Load the new laps from blow room section
on the trolley (7 laps per trolley)
Bring the trolley with laps back to carding
section
Bring the empty can and keep on the
machine
Move the filled can from the machine and
keep in the respective area
Clean the work area around the machines
Check the suction hood working condition
Clean the bruce wheel at the shift end and
collect the waste
Remove the suction hood waste (in the blow
room)
Front side top-LR
Bring the yellow bag from blow room
Move the waste collected to blow room
section yellow bag
Hand over the waste collected in the carding
section after weighment at the shift end
Front side wheel-LR
Front side bottom-LR
Back side bottom-LR
side door-LR
Return back the lap rod and cover to blow
room section
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower -
Designation Proposed Manpower -
Sl.
No
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Carding
WLS No: ESP/W/05 A
Elegant
Spinning Shifts B G
Spinning
A
WORK LOAD DETAILS SHEET
Activity Description
Tenter
C
36
t 0.063 7 15.00 13 7.47
Clean the machine at the time of lot change
Thomas O Connor table
T (M/C running time per cycle) = 480 mins per shift *7 machines = 3360 mins
t1(Average time in min taken by operator per mrh to perform necessary deferrable work while
m/c is running) = 95.66 mins
t2 (Average time in min taken by operator per mrh to perform non-deferrable work while m/c
is running ) = 225.88 mins
7 95.75%
Operator workload(%)
10 92.37%
94.76%
t (Average time in min taken by operator per mrh to perform non-deferrable work with the
machine stopped) = 10.23 mins
The above values are depicted in the graph to find out the optimum (where running efficiency
& operative workload meets) number of drums to be allotted per personnel and presented
below:
The machine efficiency and respective operative workload for the values above is found out
from the Thomas O' Connar table and tabulated below:
11 90.93%
65.74%
90.60%
98.11%
9 93.64%
No of Machines Machine Efficiency(%)
74.36%
82.67%
8
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower -
Designation Proposed Manpower -
Sl.
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Carding
WLS No: ESP/W/05 A
Elegant
Spinning Shifts B G
Spinning
A
WORK LOAD DETAILS SHEET
Activity Description
Tenter
C
From the graph, the optimum number of machine can be allotted per operator is 10 nos.
Lot change - 4 machine/(3 shifts*22 machines) = 0.06 /shift/group
Remarks:
7 8 9 10 11
Machine Efficiency(%) 95.75% 94.76% 93.64% 92.37% 90.93%
Operator Workload(%) 65.74% 74.36% 82.67% 90.60% 98.11%
0.00%
20.00%
40.00%
60.00%
80.00%
100.00%
120.00%
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________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre
Present
Manpower
2 -
Designation
Proposed
Manpower
2 -
Sl.
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A
1 t2 33.83 2.00 0.43 13.00 32.88
2 t2 33.83 2.00 0.37 13.00 28.29
3 t2 33.83 2.00 0.20 13.00 15.29
4 t2 78.93 2.00 0.21 13.00 36.57
5 t 4 2.00 0.98 13.00 8.86
6 t 4 2.00 0.50 13.00 4.52
7 t 1.579 2.00 0.40 13.00 1.43
8 t 1.579 2.00 0.51 13.00 1.83
9 t 0.33 2.00 0.17 13.00 0.12
B 0.00
1 t2 170.7 1.00 0.15 13.00 28.93
2 t2 170.7 1.00 0.43 13.00 82.93
3 t2 170.7 1.00 0.58 13.00 111.09
4 t2 170.7 1.00 0.19 13.00 36.64
5 t 4 1.00 0.98 13.00 4.43
6 t 4 1.00 0.50 13.00 2.26
7 t 3.413 1.00 0.55 13.00 2.10
8 t 1.707 1.00 0.57 13.00 1.10
9 t 0.66 1.00 0.17 13.00 0.12
Clean drafting zone and filter box once in
every two hrs.
Piece the ends during breakages
Move the LDO/6 materials cans to the
Cherry Hara D/F
WORK LOAD DETAILS SHEET
G
Change top rolls once in every two hours
Tenter
2
2
Remove the roller jam
Piece the ends during breakages
Remove the roller jam
WLS No: ESP/W/06
Clean the drafting zone and filter box
once in every two hours
Bring the full materials cans(Carding
sliver) from carding section
Replace the empty cans by the full sliver
can & join the sliver in LDO/6
Return the empty cans to the carding
section & keep in the area earmarked
Do the lot change cleaning
A
2
2
Replace the empty cans by the materials
cans & join the sliver in Cherry Hara
Do the lot change cleaning
Change top rolls once in every two hours
Place the empty cans in Cherry Hara for
doffing
Remove the full cans from cherry hara &
keep the cans in Materials cans area
Elegant
Spinning
Shifts C
Spinning
Finishing Section
Drawframe
Activity Description
Breaker
Place the empty cans in LDO/6 for
doffing
B
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre
Present
Manpower
2 -
Designation
Proposed
Manpower
2 -
Sl.
No
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WORK LOAD DETAILS SHEET
G
Tenter
2
2
WLS No: ESP/W/06
A
2
2
Elegant
Spinning
Shifts C
Spinning
Drawframe
Activity Description
B
C t1 1 1.00 2.00 13.00 2.26
The machine efficiency and respective operative workload for the values above is found out
from the Thomas O' Connar table and tabulated below:
4
83.42%
Collect waste and hand over to mixing for
weighment
3
74.77%
66.02%
t2 (Average time in min taken by operator per mrh to perform non-deferrable work while m/c
is running ) = 372.61 mins
t (Average time in min taken by operator per mrh to perform non-deferrable work with the
machine stopped) = 26.78 mins
69.80%
83.42%
92.08%
Thomas O Connor table
T (M/C running time per cycle) = 480 mins per shift *3 machines = 1440 mins
t1(Average time in min taken by operator per mrh to perform necessary deferrable work while
m/c is running) = 2.26 mins
The above values are depicted in the graph to find out the optimum (where running efficiency
& operative workload meets) number of drums to be allotted per personnel and presented
below:
5
6 57.83% 96.78%
No of Machines
Machine
Efficiency(%)
Operator workload(%)
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre
Present
Manpower
2 -
Designation
Proposed
Manpower
2 -
Sl.
No
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WORK LOAD DETAILS SHEET
G
Tenter
2
2
WLS No: ESP/W/06
A
2
2
Elegant
Spinning
Shifts C
Spinning
Drawframe
Activity Description
B
It is recommended that one operator per two breaker and one finisher machine.
Lot change - 4 R/F machine/day = 4/(3shifts*2 machine) = 0.66 /machine/shift
Remarks:
3 4 5 6
Machine Efficiency(%) 83.42% 74.77% 66.02% 57.83%
Operator Workload(%) 69.80% 83.42% 92.08% 96.78%
0.00%
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60.00%
80.00%
100.00%
120.00%
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________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre
Present
Manpower
3 -
Designation
Proposed
Manpower
3 -
Sl.
No
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1
t2 32 2 0.30 13 21.70
2
t2 32 2 0.17 13 12.29
3 t2 480 2 0.08 13 85.70
4 t1 4 2 3.17 13 28.66
5 t1 1 2 2.80 13 6.33
6 t1 1 1 2.70 13 3.05
7
t1 240 2 0.08 13 41.76
8
t 4 2 4.83 13 43.66
9
t 4 2 1.00 13 9.04
10
t 4 2 4.17 13 37.70
11
t 4.62 2 0.77 13 8.04
12
t 2.31 2 0.91 13 4.75
13
t 2.31 2 0.60 13 3.13
14
t 4.62 2 0.90 13 9.40
15
a
t2 0.26 2 36.00 13 21.15
b
t2 0.26 2 20.40 13 11.99
WLS No: ESP/W/07
Elegant
Spinning Shifts G
Spinning
Speed Frame
Tenter
Activity Description
Idle spindle
Piece the ends of Finisher Sliver
Move the full DF cans from D/F can
storage area to S/F machine& replace
empty cans.
Keep the empty cans colour wise near
the D/F
Clean the draft zone
Clean the machine floor and area
between the cans
Clean the machine floor (front side)
Clean the bottom and top clearer (while
machine is in running)
Lot Change
Put the Jodi in the empty rovings
Clean the bottom and top clearer at
every doff*
Clean the fan waste of S/F at every doff
Actually machine stops for 15 mins for
doffing. Extra time of (15-5.83=9.17
mins)
Other interruptions
Remove the Top/Bottom Roller jam
Piece the broken roving
3
WORK LOAD DETAILS SHEET
3
C A B
3 3
Put the empty cans colour wise near the
D/F
Move the full DF cans from D/F can
storage area to S/F machine& put the
sliver from can to top roller
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre
Present
Manpower
3 -
Designation
Proposed
Manpower
3 -
Sl.
No
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WLS No: ESP/W/07
Elegant
Spinning Shifts G
Spinning
Speed Frame
Tenter
Activity Description
3
WORK LOAD DETAILS SHEET
3
C A B
3 3
c
t 0.26 2 27.36 13 16.08
16
t 0.07 2 60.00 13 8.95
t1(Average time in min taken by operator per mrh to perform necessary deferrable work while
m/c is running) = 79.80 mins
Machine
Efficiency(%)
64.21%
T (M/C running time per cycle) = 480 mins per shift *2 machines = 960 mins
Calculation of workload using Thomas O Connor table:
2 82.54%
t (Average time in min taken by operator per mrh to perform non-deferrable work with the
machine stopped) = 140.75 mins
No of Machines
4 68.80% 107.04%
The machine efficiency and respective operative workload for the values above is found out
from the Thomas O' Connor table and tabulated below:
3 76.04% 88.72%
Operator workload(%)
t2 (Average time in min taken by operator per mrh to perform non-deferrable work while m/c
is running ) = 152.83 mins
The above values are depicted in the graph to find out the optimum (where running efficiency
& operative workload meets) number of drums to be allotted per personnel and presented
below:
Perform Count changing activity(replace
empty can with the full can, piece the
sliver with the roving &start the
machine)
Piece the silver from top roller to roving
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre
Present
Manpower
3 -
Designation
Proposed
Manpower
3 -
Sl.
No
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WLS No: ESP/W/07
Elegant
Spinning Shifts G
Spinning
Speed Frame
Tenter
Activity Description
3
WORK LOAD DETAILS SHEET
3
C A B
3 3
No of D/F cans to be replaced (respective machine efficiency) - 50 per shift * 5 machine = 250
cans
Lot change - 4 R/F machine/day = 4/(3shifts*5 machine) = 0.26 /machine/shift
* For applying in the formula, machine stoppage time of 15 mins is considered in t.
S/F doffers replaces 150 cans . So only remaining cans to be replaced by sider. Hence, 100 cans/ 5
machine = 20 cans/machine
Whereas in Count change, all the activity is performed, when machine is in stopped condition.
Doffers helps during count change.
Count change - 1 machine / day = 1/(3 shifts* 5 machine) = 0.066 / shift / team
During lot change, half of the machine is running condition and they change the remaining half.
Machine gets stopped only hen piecing of sliver with roving done. It is considered that all the
activities for lot change has been performed only by the tenter.
Remarks:
2 3 4
Machine Efficiency(%) 82.54% 76.04% 68.80%
Operator Workload(%) 64.21% 88.72% 107.04%
0.00%
20.00%
40.00%
60.00%
80.00%
100.00%
120.00%
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________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 2 2 2 -
Designation Proposed Manpower 2 2 2 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 1
8.67 8.67
2 2 2000
bobbin
62.07 124.14
3 2 5 doffs 48.40 96.80
4 2 5 78.70 157.40
5 2
14 14.00 28.00
6 2 2000
bobbin
s
20.00 40.00
7 2 166
cans
37.35 74.70
8 2 4 17.40 34.80
9 1
10 1
11 1 3 30.00 90.00
A 664.50
B 13
C 750.89
D 450
E 83.43%
F 2
G 83.43%
To put the empty S/F bobbins in the spindle
To keep the trolly of S/F Bobbins near the Rack
WLS No: ESP/W/08
WORK LOAD DETAILS SHEET
ELEGANT
Shifts A B C G
SPEEDFRAME
DOFFER
Activity Description
To come on duty 15 min before shift start and report
to jobber.
To bring empty S/F bobbins from Rack in plastic
tapa
PREPARATORY
To do the doffing in S/F.
To keep all S/F Bobbins colour/lot wise wise in Rack
To creel full D/F Cans in S/F and put off Empty cans
.
10.00
To keep the unwanted items in Unwanted box
To relieve the S/F sider for lunch
To clean Preparatory Deptt. With Floor cleanning
Brush time to time
To keep the clg.items in clg. Box
5 10.00
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Net Available man-mins
Proposed Utilisation(%)
Remarks:
Present Utilisation(%)
Proposed Manpower per shift
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 1 1 1 -
Designation Proposed Manpower 1 1 1 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
1 1 24.33 24.33
2 1 1 30.83 30.83
3
1 1 15.00 15.00
4
1
5 1
6 1
7
1
8
1 3 61.67 61.67
9
1 1
15.00 15.00
10 1 1 30.00 30.00
11
1 1
12.00 12.00
12
1 1
12.17 12.17
13
1
43.00 43.00
A 294.00
B 13
C 332.22
D 450
E 73.83%
F 1
G 73.83%
To attend Hand shortage at shift change time
To make attendence report of Preparatory Section and
hand over it time keeper.
WLS No: ESP/W/09
WORK LOAD DETAILS SHEET
ELEGANT
Shifts A
20.00 20.00
To Check the wrapping of D/F of new lots
B C
To distrubite the Attandance Cards at the end of the
Shift
G
CARDING,D/F,S/F
JOBBER
Activity Description
To come 30 min before shift change and take charge of
deptt and write in charge Register.
30.00 30.00
To maintain house keeping during the shift.
PREPARATORY
Remarks:
Ensure colorwise segregation of S/F bobbin & D/F
cans
To lookafter all work of Preparatory Section workers
and maintain all systems 1
To see mateial setting and do lot change/count change
as per planning and Deptt Required
To attend all the abnormalities shown by incoming
shift at the charge time.
To relieve the D/F Tenter for lunch
To keep the D/F Material covered with polythene sheet
To Check the wrapping of Carding of new lots
4
Proposed Manpower per shift
Proposed Utilisation(%)
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 1
Designation Proposed Manpower - - - 1
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 5 57.50 57.50
2 1 65 trolleys 232.05 232.05
A 289.55
B 13
C 327.19
D 480
E 68.16%
F 1
G 68.16%
WLS No: ESP/W/10
WORK LOAD DETAILS SHEET
ELEGANT
Shifts A B C G
Remarks:
PREPARATOTY
Remove the trolley Jam
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
SPEEDFRAME
JAM CUTTER
Activity Description
Collect trolleys from the dept.
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre
Present
Manpower
9 -
Designation
Proposed
Manpower
9 -
Sl.
No
Crew
Size
Freq/
Shift
No of
Mach
ine
Basic
Time
(Mins)
Allowan
ce(%)
Total
Time
(Mins)
1 1 576 1 0.13 13 84.61
2 1 1 1 20.52 13 23.19
3 1 1 1 15.00 13 16.95
4 1 1 1 15.00 13 16.95
5
1 41.6 3 0.54 13 76.15
1 41.6 3 0.22 13 31.03
1 41.6 3 0.40 13 56.41
6
1 0.012 3 4.00 13 0.16
1 0.012 3 4.00 13 0.16
7
1 0.051 3 4.00 13 0.69
1 0.051 3 4.00 13 0.69
8
1 18.9 3 0.02 13 1.47
1 18.9 3 0.41 13 26.27
1 18.9 3 0.02 13 1.47
9 1 1 1 5.00 13 5.65
A 341.86
B 480
C 71.22%
Net Available man-mins
Present Utilisation(%)
Count change
Remove the top clearer, clean and keep
on the lammba
Put the top clearer on the machine after
the count change over
S/F Roving Change
Basic Workload per Shift ( in man minutes)
Put the top clearer on the machine after
the count change over
Clean the creel
To attend idle spindles in his m/c
Remove roller lapping using hexablade
knife
Piece the broken threads
Bring the S/F roving near the machine
from the S/F roving storage area
Replace the empty rovings with the full
roving
Keep the empty rovings back in the rack
To collect pneumafil waste and hand
over it to mixing for weighment at the
shift end.
Clean the Jockey pulley
Ringframe-LR 9
Roving thread piecing
Lot change
Remove the top clearer, clean and keep
on the lammba
C G
Spinning
Activity Description
Clean the Top clearer
Clean Drafting zone
9
Sider 9 9
WLS No: ESP/W/11
WORK LOAD DETAILS SHEET
Elegant Spinning
Shifts A B
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre
Present
Manpower
9 -
Designation
Proposed
Manpower
9 -
Sl.
No
Crew
Size
Freq/
Shift
No of
Mach
ine
Basic
Time
(Mins)
Allowan
ce(%)
Total
Time
(Mins)
Ringframe-LR 9
C G
Spinning
Activity Description
9
Sider 9 9
WLS No: ESP/W/11
WORK LOAD DETAILS SHEET
Elegant Spinning
Shifts A B
5
2880 (5*576) 77.55% 98.24%
2592 (4.5*576) 79.33% 91.48%
The above values are depicted in the graph to findout the optimum (where running efficiency
& operative workload meets) number of drums to be allotted per personnel and presented
below:
Running Efficiency
() (%)
Operator
workload(%)
2304 (4*576) 81.20% 84.73%
2016 (3.5*576) 83.15% 77.98%
The running efficiency is arrived by the formula provided in the research paper : The
Efficiency of N machines Uni-Directionally patrolled by single operative by
Mr.C.Mack,T.Murphy and N.L.Webb,Journal of the Royal Statistical Society, (1957).
r = (b-1) / [ gN{K+(b-1)C}]
1728 (3*576) 85.20% 71.22%
The running efficiency is calculated using the above formula for different number of drums
and tabulated below:
No of Drums
g - 0.0004901, N - 1728 (3*576), C- 0.22 , K-0.03
1728
(3*576)
2016
(3.5*576)
2304
(4*576)
2592
(4.5*576)
Running Efficiency () (%) 85.20% 83.15% 81.20% 79.33%
Operator workload(%) 71.22% 77.98% 84.73% 91.48%
0.00%
10.00%
20.00%
30.00%
40.00%
50.00%
60.00%
70.00%
80.00%
90.00%
100.00%
E
f
f
i
c
i
e
n
c
y
(
%
)
Ringframe-LR
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre
Present
Manpower
9 -
Designation
Proposed
Manpower
9 -
Sl.
No
Crew
Size
Freq/
Shift
No of
Mach
ine
Basic
Time
(Mins)
Allowan
ce(%)
Total
Time
(Mins)
Ringframe-LR 9
C G
Spinning
Activity Description
9
Sider 9 9
WLS No: ESP/W/11
WORK LOAD DETAILS SHEET
Elegant Spinning
Shifts A B
* Time lost due to doffing,Travellours change,Lot/Count change and maintenance is collected from
the management
Speedframe rovings is changed mainly during the lot change and Count change. As the activities
are performed during lot & count change it is being considered under the doffers workload. But
small percentage(30%) of S/F rovings is being changed by sider ( while running).Number of
rovings to be feed per ringframe per shift equals to 63 rovings.
Actual Machine efficiency (%)=Machine Running hours* Running efficiency
EX: For 1728 Spindle Actual machine efficiency (%) = 7.36 hours *0.852 = 6.27 hours/shift
From the graph, the optimum number of drums to be allotted per operator comes to 3.5 to 4
machine. In practical , it is not possible to allocate 3.75 machine and also that the R/F
efficiency is critical. It is suggested to provide one operator for three machines.
Machine Efficiency: (Sample calculation)
Machine available hours * (Time lost due to doffing,Travellours change,Lot/Count change and
maintenance) = Machine running hours ( 8 hours * 92 % = 7.36 hours)
Remarks:
Count change - 1 machine / day = 1/(3 shifts* 26 machine) = 0.012 / shift
Lot Change- 4 machine / day = 4/ (26 machine*3 shift) = 0.0512 / shift
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 7 7 -
Designation Proposed Manpower 7 7 -
Sl.
No
Crew
Size
Freq/
Shift
No of
Spindl
es/mac
hine
Basic
Time
(Mins)
Total
Time
(Mins)
1 7 1 5.00 35.00
2
a 4 52 2.56 532.48
b 4 52 576 2.820 586.56
c 4 52 0.70 145.60
d 4 52 1.00 208.00
3
a 1 2 576 0.03 34.56
b 1 2 576 0.05 57.60
c 1 2 576 0.03 34.56
d 1 2 1 3.50 7.00
4
a 1 0.16 576 0.018 1.61
b 1 0.66 576 0.02 8.74
c 1 0.66 576 0.07 26.61
d 1 0.66 576 0.41 155.87
e 1 0.66 576 0.05 19.01
f 1 0.66 576 0.02 8.74
5
a 1 0.16 1 1.98 0.32
b 1 0.16 576 0.012 1.09
c 1 0.16 576 0.078 7.17
d 1 0.16 1.98 0.32
e 1 0.16 576 0.018 1.61
f 1 0.16 576 0.02 2.12
Put the new ring travellour in the spindle
Close the doom(2 sides)
WLS No: ESP/W/12
WORK LOAD DETAILS SHEET
Elegant Spinning
Shifts A B G C
Spinning
Join the thread roving and bobbin
Take trays, got to autoconer area, Collect the
empty R/F bobbins from Autoconer storage
area,Reach the machine spot
Keep the collected R/F bobbin trays in the R/F
Sorting area
Bobbin changing
Remove the filled R/F bobbin from the spindle &
Put the empty R/F bobbin in the R/F spindle(144
spindle timing)
Arrange the S/F rovings from rack to trolley
Count Change
Bring the S/F roving near the machine from the
S/F roving storage area
Open the doom(2 sides)
Move the empty trolley back to S/F rovings area
Remove the lammba for the old count(288 spindle)
Put the new count lammab on the machine(288
spindle)
Clean the machine area after ring travellour change
Bring the S/F roving near the machine from the
S/F roving storage area(40 rovings/trolley)
Remove the empty S/F bobbins from the R/F &
Keep it in the trolley
Arrange the S/F rovings from rack to trolley
Join the thread roving and bobbin
Put the S/F roving in the creel
Join the thread after ring traveller put
Lot Change
7
7
Remove the Old ring travellour from the spindle
Ringframe
Doffers
Activity Description
Shift Release activity
Ring Travellour Change
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 7 7 -
Designation Proposed Manpower 7 7 -
Sl.
No
Crew
Size
Freq/
Shift
No of
Spindl
es/mac
hine
Basic
Time
(Mins)
Total
Time
(Mins)
WLS No: ESP/W/12
WORK LOAD DETAILS SHEET
Elegant Spinning
Shifts A B G C
Spinning
7
7
Ringframe
Doffers
Activity Description
g 1 0.16 576 0.05 0.01
h 1 0.16 576 0.07 6.45
i 1 0.16 576 0.41 0.07
j 1 0.16 576 0.02 2.12
6
1 1 2 10.00 20.00
1 1 806 0.02 14.11
1 1 806 0.04 31.34
7 1 2.00 14.00
7 1 1 5 63.00 315.00
A 2277.66
B 8
C 2459.87
D 480
E 73.21%
F 7
G 73.21%
Lot Change - 4 machine/day = 4/(3shifts*2 team) = 0.66 / shift / team
Count change - 1 machine / day = 1/(3 shifts* 2 team) = 0.16 / shift / team
Move the empty trolley to S/F rovings area
Cleaning
Remove the remaining threads from the S/F
rovings
To do the foot step area cleaning of the machine
Arrange the cleaned S/F roving from trolley to rack
Clean the doffing trolley wheel checking &
cleaning
4 Doffings /machine /shift = 13*4 =52 times/ shift/ team
Rovings consumption- (62 rovings / machine/shift) * (13 machines / team )= 806 rovings / shift /
team
One doffing team consists of 7 doffers and one co-ordinator.
Relieve the sider for the break(Tea,breakfast or
lunch)
As reliever is provided, net available man mins becomes 480 mins. As the above activity frequency
is for 480 mins.
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )(Total-13%-5% relieved by reliever+8%
added in the workload)
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
13 R/F machine for one doffing team
Rings travellor change- 2 machines / team /shift
Put the new S/F roving in the creel
Proposed Utilisation(%)
Remove the empty S/F rovings from the R/F &
Keep it in the trolley
Remarks:
Join the thread roving and bobbin
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 1 1 1 -
Designation Proposed Manpower 1 1 1 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 1 15.00 15.00
2 1 2 63 125.00
2
3
4
A 140.00
B 13
C 158.20
D 450
E 35.16%
F 1
G 35.16%
The above job is supervisory in nature.
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Remarks:
Discussing with the supervisors, siders
Perform the scheduled activities like ring travellours
change, machine cleaning and lot change/count
change with the doffers
Proposed Utilisation(%)
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
WLS No: ESP/W/13
WORK LOAD DETAILS SHEET
Elegant Spinning
Shifts A B C G
Spinning
Relieve the ringframe-doffers for breaks
Ringframe
Doffer-Leader
Activity Description
Shift Release activity
Co-ordinate the doffing team effectively for
minimising the machine downtime for changover
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 2 2 2 -
Designation Proposed Manpower 2 2 2 -
Sl.
No
Crew
Size
Freq /
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 12 63 750.00
A 750.00
B 13
C 847.50
D 450
E 94.17%
F 2
G 94.17%
Remarks:
WLS No: ESP/W/14
WORK LOAD DETAILS SHEET
Elg Spg
Shifts A
Ringframe
Activity Description
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Relieve-twelve ringframe-doffers for breaks
Lunch-30 mins, Tea - 10 mins, Personal Intervention(5%) - 23 mins .Total - 63
mins/shift/person
B C G
Spinning
Proposed Manpower per shift
Proposed Utilisation(%)
Reliever-Doffers
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 1 1 1 -
Designation Proposed Manpower 1 1 1 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
1 1 25.00 25.00
2 1 1 7.83 7.83
3 1 1 5.00 5.00
4 1 1 30.00 30.00
5
1 1 5.00 5.00
6 1 4 31.20 31.20
7
8
9
10
11
12
1 3 120.00 120.00
13
1
14 1
15
1 1 10.00 10.00
A 334.03
B 13
C 377.46
D 450
E 83.88%
F 1
G 83.88%
WLS No: ESP/W/15
WORK LOAD DETAILS SHEET
ELEGANT
Shifts A B C
To attend hands shortage at shift change time.
To make attendance report of R/F and handover it
to time keeper.
To take the round of the deptt. With S/I
To distribute the work to the deptt. Worker, sider,
doffer, reliever
RING FRAME
To collect the attendance catds of R/F workers.
To take the charge of S/F materials.
90.00
To look after all work of R/F workers and
maintain all systems in R/F section
To engage one hand for floor cleaning
To monitor dept. waste (20 % of shift time)
G
RING FRAME
JOBBER
Activity Description
To come 30 min before shift change and take
charge of dept. and write charge register
To make ringtraveller change and handover old rtr
to shift officer 10.00
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
To engage one hand for bobbin sorting
To see material settling and do lot change/count
change as per planning.
Total Workload ( in man minutes )
Net Available man-mins
Proposed Utilisation(%)
Remarks:
10.00
To help for gaiting
To distribute the attendance cards at the end of the
shift
Present Utilisation(%)
Proposed Manpower per shift
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 1 1 1 -
Designation Proposed Manpower 1 1 1 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
1 1 10.00 10.00
2 1
3 1
4
1
5 1
6
1
7
1 2 23.40 23.40
8 1 1 30.00 30.00
A 304.60
B 13
C 344.20
D 450
E 76.49%
F 1
G 76.49%
WLS No: ESP/W/16
WORK LOAD DETAILS SHEET
ELEGANT
Shifts A B C G
RINGFRAME
RINGFRAME
BOBBIN SORTER
Activity Description
To come on duty 15 min before shift start and report to
RF jobber.
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
241.20
To clean the m/c top area in off ends side
To relieve RF checker For lunch.
241.20
To keep empty doffing tapas from A/C in proper way.
To repaire faulty RF bobbins and hand over to A/C.
To sort RF bottom bobbins and send it to A/C lotwise
To maintain house keeping in his work area during the
shift.
To sort RF bobbins lotwise and colorwise.
5
4
0
5
9

b
o
b
b
i
n
s
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Remarks:
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 1 1 1 -
Designation Proposed Manpower 1 1 1 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
1 1 20.00 20.00
2
1 1
3 1 1
4
1 1 30.84 30.84
5
1 26.00 26.00
6 1
7
1
8
1 13.00 13.00
9 1
10 1
11
1 23.70 23.70
12
1
8.40 8.40
13 1 1 63.00 63.00
A 318.26
B 13
C 359.63
D 450
E 79.92%
F 1
G 79.92%
WLS No: ESP/W/17
WORK LOAD DETAILS SHEET
ELEGANT
Shifts A B C G
RINGFRAME
94.80
To Separate faulty RF bobbins and make their
report.
RINGFRAME
CHECKER
Activity Description
To come 30 min before shift change and report to
R/F jober
To check the colour code of S/F & RF bobbins and
new lots , final lots.. 25.00
Basic Workload per Shift ( in man minutes)
13.52
To write the RF hanks in hank Register.
To hand over Final lot material to A/C after
checking
25.00
To take charge of materials from B/R to R/F
To Check & make report of all lots running from
B/R to R/F.
To put sample of new lot in sample register
To check RF doffs during Shift
94.80
To check lot change Clg. &shift M/C cleaning. in
R/F.
To make rport of idle spindles in R/F.
13.52
To take the round of R/F after every 2 Hrs to check
the colour & write in the register
To relieve the Bobbin sorter for Lunch & tea
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Remarks:
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 1 1 1 -
Designation Proposed Manpower 1 1 1 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
1 1 10.50 10.50
2
1 8 170.42 170.42
3 1 23 24.13 24.13
4 1 4 16.00 16.00
5
1 12 96.00 96.00
6
1 8 3.40 3.40
7
1 1 4.50 4.50
8
1 4 16.88 16.88
A 341.83
B 13
C 386.27
D 450
E 85.84%
F 1
G 85.84%
Present Utilisation(%)
Net Available man-mins
RINGFRAME
To clean floor in RF section in between m/cs and allies
out side the m/cs by Plate form brush
To collect roller bonda from RF waste boxes
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
To come on duty 15 min before the shift starts and
report to RF jobber.
WLS No: ESP/W/18
WORK LOAD DETAILS SHEET
ELEGANT
Shifts A G
RINGFRAME
FLOOR CLEANER
Activity Description
B
Proposed Utilisation(%)
Remarks:
Proposed Manpower per shift
To collect waste from Over head Blowers .
To do sorting of roller bonda, shadewise and keep them
in separate bags
To collect sweeping waste from floor and keep it
separate from other wastes.
To send Roller bonda waste, Swpg. Waste, & O.H.B.
waste to mxg. For weighment.
To move Magnet trolly in whole RF section to collect
old Rtrs from floor.
C
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 1 1 1 -
Designation Proposed Manpower 1 1 1 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 1
2 1 1
3
1 1 45.00 45.00
4 1 1 40.00 40.00
5 1 1 12.00 12.00
6 1 4 32.00 32.00
7 1 1 35.00 35.00
8 1 1 45.00 45.00
9 1 1 15.00 15.00
A 249.00
B 13
C 281.37
D 450
E 62.53%
F 1
G 62.53%
WLS No: ESP/W/19
WORK LOAD DETAILS SHEET
ELEGANT
Shifts A
Write down doff balance and R/F setup, autoconer
drum setup & change as per doff balance & R/F
setup
Collect all workers card and adjust hands
G
POST SPG
25.00 25.00
Check running material, cone tip, bobbin color
Total Workload ( in man minutes )
Net Available man-mins
B C
Check A/C idle drums and make a report
Write m/c efficiency and production details
AUTOCONER
JOBBER
Activity Description
Take charge of his duty
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Remarks:
Make attendance report
Syestematically adjust all empty & full tapa
All new lot sample pasted in sample register
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 1 1 1 -
Designation Proposed Manpower 1 1 1 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 1
2
1 1
3 1 1 45.00 45.00
4
1
10
samples
30.00 30.00
5 1 1 30.00 30.00
6
1 1 60.00 60.00
7
1 1 46.00 46.00
8 1 1 15.00 15.00
9 1 1 15.00 15.00
10
1 1/3 36.00 36.00
A 302.00
B 13
C 341.26
D 450
E 75.84%
F 1
G 75.84%
G
POST SPG
25.00 25.00
Note all m/c settings drum wise, count wise, bobbin
and cone color in setting register and instruct
winder
WLS No: ESP/W/20
WORK LOAD DETAILS SHEET
ELEGANT
Shifts A
All new lot sample pasted in sample register
Check TFO m/c vereator and tension setting and
note in register
B C
AUTOCONER
CHECKER
Activity Description
Take charge of his duty
Make cut report and hand over to shift supervisor
Check and note single pack material random cone
weight
Collect final lot from ringframe checker and check
Check each cone for faults and inform jobber and
shift supervisor
Note cheese winding breakage and report to jobber
and shift supervisor
Make TFO m/c idle report
Basic Workload per Shift ( in man minutes)
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Remarks:
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre
Present
Manpower
1 1 -
Designation
Proposed
Manpower
1 1 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Allowa
nce (
%)
Total
Time
(Mins)
1
1 26.61 0.75 13 22.55
2 1 26.61 0.10 13 3.01
3
1 7983 0.030 13 270.62
4 1 26.61 0.08 13 2.41
5 1 932 0.06 13 63.19
6 1 466 0.12 13 63.19
7
1 235 0.10 13 27.46
8
1 2 2.00 13 4.52
A 456.95
B 480
C 95.20%
The above values are depicted in the graph to findout the optimum (where running
efficiency & operative workload meets) number of drums to be alloted per personnel and
presented below:
70 97.83% 111.06%
60 98.92% 95.20%
Present Utilisation(%)
The running efficiency is arrived by the formula provided in the research paper : The
Efficiency of N machines Uni-Directionally patrolled by single operative by
Mr.C.Mack,T.Murphy and N.L.Webb,Journal of the Royal Statistical Society, (1957).
The running efficiency is calculated using the above formula for different number of drums
and tabulated below:
No of Drums
Running Efficiency
() (%)
Operator workload(%)
r = (b-1) / [ gN{K+(b-1)C}]
g - 0.06469, N - 60, C - 0.09, K - 0.20
Collect the waste from the machine
Basic Workload per Shift ( in man minutes)
Net Available man-mins
Keep the empty tray aside
Attend the thread cuts in spindles
Attend the thread cuts in spindles
Take the empty auto cone from the machine
tray, remove the filled cone and put the
empty cone on the machine and start the
machine
Activity Description
Bring the R/F Bobbin tray from R/F storing
section ( in Tray)
Take the trays and keep on the trolley
Put the R/F Bobbins in the machine drum
Autoconer-Savio 1
Winder 1
WLS No: ESP/W/21
WORK LOAD DETAILS SHEET
Elegant Spinning
Shifts A B C G
Post Spinning
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre
Present
Manpower
1 1 -
Designation
Proposed
Manpower
1 1 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Allowa
nce (
%)
Total
Time
(Mins)
Activity Description
Autoconer-Savio 1
Winder 1
WLS No: ESP/W/21
WORK LOAD DETAILS SHEET
Elegant Spinning
Shifts A B C G
Post Spinning
* Time lost due to doffing,bobbin reject,extracycle,splice and bobbin change is collected from the
management
From the graph, the optimum number of drums to be alloted per operator is 60 drums
Remarks:
No of bobbins - 7750 bobbins/shift/60 drums
Rejection (3 %) - 7750 * 3% = 232.5 bobbins . Total - 7750 +233= 7983 bobbins /shift
Machine Efficiency: (Sample calculation)
Machine available hours * (Time lost due to doffing,bobbin reject,extracycle,splice,bobbin
change) = Machine running hours ( 8 hours * 76 % = 6.08 hours)
Actual Machine efficiency (%)=Machine Running hours* Running efficiency
EX: For 60 drums, Actual machine efficiency (%) = 6.08 hours *0.9892 = 6.014hours/shift
60 70
Running Efficiency ()
(%)
98.92% 97.83%
Operator workload(%) 95.20% 111.06%
85.00%
90.00%
95.00%
100.00%
105.00%
110.00%
115.00%
E
f
f
i
c
i
e
n
c
y
(
%
)
Autoconer-Savio
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre
Present
Manpower
6 6 -
Designation
Proposed
Manpower
6 6 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Allowa
nce (
%)
Total
Time
(Mins)
1
1 24.83 0.75 13 21.05
2 1 24.83 0.10 13 2.81
3 1 7450 0.030 13 252.56
4 1 24.83 0.08 13 2.24
5 1 868 0.06 13 58.85
6 1 434 0.12 13 58.85
7
1 217 0.10 13 25.35
8
1 2 2.00 13 4.52
A 426.23
B 480
C Present Utilisation(%) 88.80%
5
The above values are depicted in the graph to findout the optimum (where running
efficiency & operative workload meets) number of drums to be alloted per personnel and
presented below:
70 98.08% 103.59%
The running efficiency is arrived by the formula provided in the research paper : The
Efficiency of N machines Uni-Directionally patrolled by single operative by
Mr.C.Mack,T.Murphy and N.L.Webb,Journal of the Royal Statistical Society, (1957).
r = (b-1) / [ gN{K+(b-1)C}]
60 99.09% 88.80%
The running efficiency is calculated using the above formula for different number of drums
and tabulated below:
No of Drums
Running Efficiency
() (%)
Operator workload(%)
Take the empty auto cone from the machine
tray, remove the filled cone and put the
empty cone on the machine and start the
machine
Activity Description
Bring the R/F Bobbin tray from R/F storing
section ( in Tray)
Take the trays and keep on the trolley
Put the R/F Bobbins in the machine drum
g - 0.062789, N - 60, C - 0.09 , K - 0.20
Collect the waste from the machine
Basic Workload per Shift ( in man minutes)
Net Available man-mins
C G
Post Spinning
Keep the empty tray aside
Attend the thread cuts in spindles
Attend the thread cuts in spindles
Autoconer-
Muratech
6
Winder 6
WLS No: ESP/W/21 & A
WORK LOAD DETAILS SHEET
Elegant Spinning
Shifts A B
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre
Present
Manpower
6 6 -
Designation
Proposed
Manpower
6 6 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Allowa
nce (
%)
Total
Time
(Mins)
Activity Description
C G
Post Spinning
Autoconer-
Muratech
6
Winder 6
WLS No: ESP/W/21 & A
WORK LOAD DETAILS SHEET
Elegant Spinning
Shifts A B
Actual Machine efficiency (%)=Machine Running hours* Running efficiency
EX: For 60 drums Actual machine efficiency (%) = 5.68 hours *0.9909 = 5.62 hours/shift
* Time lost due to doffing,bobbin reject,extracycle,splice and bobbin change is collected from the
management
Remarks:
No of bobbins - 7233 bobbins/shift/60 drums
3 % Bobbin rejection - 7449 bobbins /shift
From the graph, the optimum number of drums to be alloted per operator is 60 drums
Machine Efficiency: (Sample calculation)
Machine available hours * (Time lost due to doffing,bobbin reject,extracycle,splice,bobbin
change) = Machine running hours ( 8 hours * 71 % = 5.68 hours)
60 70
Running Efficiency () (%) 99.09% 98.08%
Operator workload(%) 88.80% 103.59%
80.00%
85.00%
90.00%
95.00%
100.00%
105.00%
E
f
f
i
c
i
e
n
c
y
(
%
)
Autoconer-Muratech
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 1 1 1 -
Designation Proposed Manpower 1 1 1 -
Sl.
No
Crew
Size
Freq /
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 4 63 250.00
2
1 2 17.42 34.84
3
1 7 1.88 13.16
4
1 3 2.00 6.00
5
1 1 10.00 10.00
A 314.00
B 13
C 354.82
D 450
E 78.85%
F 1
G 78.85%
Clean the full machine with the compressed air(open the
pipe, clean and keep the pipe aside)
Yarn trap checking
WLS No: ESP/W/22
WORK LOAD DETAILS SHEET
Elegant Spinning
Shifts A B C
Time for wax application per machine - 16.8 mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Remarks:
Autoconer
Reliever-A/C Winder
Activity Description
Basic Workload per Shift ( in man minutes)
Lunch-30 mins, Tea - 10 mins, Personal Intervention(5%) - 23 mins . Total - 63 mins/shift/person
G
Post Spinning
Attend cutting drum jam(if any)
Collect the hard waste and handover and inform to
supervisor
Applying wax to machine is not considered ,because the activity is not being performed presently.
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Net Available man-mins
Relieve - Four autoconer-tenter's for breaks
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 1 1 1 -
Designation Proposed Manpower 1 1 1 -
Sl.
No
Crew
Size
Freq /
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 26 0.33 8.58
2 1 26 2.01 52.26
3 1 26 0.330 8.58
4 1 51.23 0.38 19.47
5 1 15.37 1.67 25.67
6 1 51.23 0.28 14.35
7 1 7 1 7.00
8 1 3 63.00 189.00
A 324.90
B 13
C 367.14
D 450
E 81.59%
F 1
G 81.59%
G
Post Spinning
Collect cones from the autoconer belt
conveyor(backside) and keep on the trolley(60 cones -
Keep the trolley near the cheese winding area(60
cones/trolley)
Lunch-30 mins, Tea - 10 mins, Personal Intervention(5%) - 23 mins . Total - 63
mins/shift/person
WLS No: ESP/W/23
WORK LOAD DETAILS SHEET
Elegant Spinning
Shifts A B C
Autoconer
Doffer
Activity Description
Take the empty trolley from cheese winding area
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Net Available man-mins
Collect the empty autocones from rack and come to
machine(30 cones)
Arrange the cones on the machine slanting
portion(100 cones =1.67 mins)
Go back to rack
Collect back the remaining cones of last batch if any
Total Cones - 1537 cones / (60 cones per trolley) = 26 trolleys
Relieve the winder-tenter for
breaks(lunch/breakfast/tea/personal needs)
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Remarks:
Autoconer Muratech - 217 cones/shift * 6 machine = 1302 cones
Autoconer Savio - 235 cones/shift * 1 machine = 235 cones
Basic Workload per Shift ( in man minutes)
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 2 2 2 -
Designation Proposed Manpower 2 2 2 -
Sl.
No
Crew
Size
Freq /
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 55881 0.01140 637.04
2 1 32 0.94 30.00
3 1 16 2.000 32.00
4 1 16 0.75 12.00
5 1 32 0.16 5.17
6 1 2 0.69700 1.39
7 1 1118 0.04200 46.96
8 1 2 0.70000 1.40
9 1 1118 0.00700 7.83
A 773.79
B 14
C 882.12
D 450
E 98.01%
F 2
G 98.01%
WLS No: ESP/W/24
WORK LOAD DETAILS SHEET
Elegant Spinning
Shifts A
Clean the belt conveyor for jam and remove the
threads at the sides
Arrange the empty trays for segregation purpose(4 -5
different trays)
G
Post Spinning
Autoconer
Bobbin sorter
Activity Description
B C
Sort the empty R/F bobbins @ autoconer belt
Take the full bobbins/half bobbins and put on the
autoconer tenter trays
Remarks:
No of bobbins fed per machine per shift - 7750 nos
Clean the spilled bobbins in and around the machine
Clean the bobbin for the remaining thread
Basic Workload per Shift ( in man minutes)
Move the trays to Yarn conditioning room
Clean the bobbins using the thread cleaning machine
Come back to machine area
Segregate the bobbins colour wise
Rejection ( 3%) - 233 nos
Total bobbins to be sorted - 7750 +233 = 7983 nos *7 machines = 55881 nos
No of bobbins to be cleaned for the remaining threads using machine - 7983*2% *7 machines =
1118 nos
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 1 1 1 -
Designation Proposed Manpower 1 1 1 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 1 10.00 10.00
2 1 2 24.00 24.00
3 1 5 225.00 225.00
4 1 1 20.00 20.00
A 279.00
B 13
C 315.27
D 480
E 65.68%
F 1
G 65.68%
POST SPG
Check and do TFO overhead dust box cleaning.
Do sweeping and collect hard waste
WLS No: ESP/W/25
WORK LOAD DETAILS SHEET
ELEGANT
Shifts A B C G
AUTOCONER
FLOOR CLEANER
Activity Description
Take charge of his duty
Dispose scrap in scrap yard
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Remarks:
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre
Present
Manpower
4 -
Designation
Proposed
Manpower
4 -
Sl.
No
Crew
Size
Freq/
Shift/s
pindle
No of
spindle
Basic
Time
(Mins)
Allowa
nce
(%)
Total
Time
(Mins)
1 1 2.625 120 0.0600 13 21.36
2 1 2.625 120 0.3440 13 122.45
3 1 5.25 120 0.1570 13 111.77
4 1 5.25 120 0.0350 13 24.92
5 1 5.25 120 0.0270 13 19.22
6 1 5.25 120 0.0192 13 13.67
7 1 5.25 120 0.0200 13 14.24
8 1 2.625 120 0.228 13 81.16
9 1 1 1 15.000 13 16.95
A 425.72
B 480
C 88.69%
1
140 83.37% 102.89%
r = (b-1) / [ gN{K+(b-1)C}]
g - 0.01 , N - 120 , C - 0.228 , K - 0.05
120 85.40% 88.69%
130 84.37% 95.79%
The running efficiency is calculated using the above formula for different number of drums and
tabulated below:
No of Drums
Running
Efficiency ()
Operator workload(%)
Total Workload per Shift ( in man minutes)
Net Available man-mins
Present Utilisation(%)
The running efficiency is arrived by the formula provided in the research paper : The Efficiency
of N machines Uni-Directionally patrolled by single operative by Mr.C.Mack,T.Murphy and
N.L.Webb,Journal of the Royal Statistical Society, (1957).
Bring the empty cheese cone from the
rack & keep on the machine
Move the trolley to cheese storage area
near the TFO
Attend the thread break
Clean the machine
Replace the empty auto cone with full
autocone & join
Replace the full cheese cone with empty
cheese cone
Write the number on the cheese cone
using chalk
Collect full cheese cone from machine
table and keep on trolley
4
Tenter 4 4
Activity Description
Keep the auto cone from trolley to the
machine table
Cheesewinding-
RJK
4
WLS No: ESP/W/27
WORK LOAD DETAILS SHEET
Elegant Spinning
Shifts A B C G
Post Spinning
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre
Present
Manpower
4 -
Designation
Proposed
Manpower
4 -
Sl.
No
Crew
Size
Freq/
Shift/s
pindle
No of
spindle
Basic
Time
(Mins)
Allowa
nce
(%)
Total
Time
(Mins)
4
Tenter 4 4
Activity Description
Cheesewinding-
RJK
4
WLS No: ESP/W/27
WORK LOAD DETAILS SHEET
Elegant Spinning
Shifts A B C G
Post Spinning
* Time lost due to doffing,general cleaning,Lot/Count change,electrical and maintenance cleaning is
collected from the management
Machine available hours * (Time lost due to doffing,general cleaning,Lot/Count change,electrical and
maintenance cleaning) = Machine running hours ( 8 hours * 78 % = 5.76 hours)
Actual Machine efficiency (%)=Machine Running hours* Running efficiency
EX: For 120 drums Actual machine efficiency (%) = 5.76 hours *0.8540 = 4.919 hours/shift
Remarks:
To calculate operators workload,480 mins is taken as net available manmins. Because, one
person (operator or reliever) present near the machine for 480 mins.
The above values are depicted in the graph to findout the optimum (where running efficiency &
operative workload meets) number of drums to be alloted per personnel and presented below:
From the graph, the optimum number of drums to be alloted per operator is 120 drums
Machine Efficiency: (Sample calculation)
120 130 140
Running Efficiency () (%) 85.40% 84.37% 83.37%
Operator workload(%) 88.69% 95.79% 102.89%
0.00%
20.00%
40.00%
60.00%
80.00%
100.00%
120.00%
E
f
f
i
c
i
e
n
c
y
(
%
)
Cheesewinding-RJK
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 1 1 1 -
Designation Proposed Manpower 1 1 1 -
Sl.
No
Crew
Size
Freq /
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 5 63 312.50
A 312.50
B 13
C 353.13
D 450
E 78.47%
F 1
G 78.47%
WLS No: ESP/W/28
WORK LOAD DETAILS SHEET
Elg Spg
Shifts A B C G
Post Spinning
Basic Workload per Shift ( in man minutes)
Cheese Winding
Reliever-Winder
Activity Description
Relieve-Five cheese winding-tenter for breaks
Lunch-30 mins, Tea - 10 mins, Personal Intervention(5%) - 23 mins . Total - 63
mins/shift/person
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Remarks:
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 1
Designation Proposed Manpower - - - 1
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 75 cones 120.00 120.00
2 1
100
bobbins
64.00 64.00
4 1 98 cones 60.00 60.00
5 1 20 cones 30.00 30.00
6 1
2
lots(2kg)
20.00 20.00
7 1 15 cones 20.00 20.00
8 1 72 cones 30.00 30.00
A 344.00
B 13
C 388.72
D 480
E 80.98%
F 1
G 80.98%
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Basic Workload per Shift ( in man minutes)
Processing of defective bobbins(R/F) for 2nd quality
Rewinding of SQC tested TFO cones
Processing of TFO broken tape, zero TPI(at top) to
2nd quality
Preparation of pair of final single cone
Remarks:
C G
POST SPG
Rewinding of single cones to remove jali, double etc
Rewinding of classimate cones
CHEESE WINDING
REWINDER
Activity Description
Rewinding of packing rejection
WLS No:ESP/W/29
WORK LOAD DETAILS SHEET
ELEGANT
Shifts A B
________________________________________________________________________________________
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Department
Section
Work Centre Present Manpower 1 1 1 -
Designation Proposed Manpower 1 1 1 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 1
2 1 1
3 1 1 36.28 36.28
4 1 3 46.46 46.46
5 1
6 1
7 1 4 27.40 27.40
8 1 5 22.50 22.50
9 1 1 79.65 79.65
10 1 1 5.00 5.00
11 1 2 11.00 11.00
12 1 4 12.00 12.00
13 1 1 55.31 55.31
14 1 1 13.27 13.27
15 1 1 12.50 12.50
16 1 1 12.50 12.50
A 382.42
B 13
C 432.14
D 450
E 96.03%
F 1
G 96.03%
WLS No: ESP/W/30
WORK LOAD DETAILS SHEET
ELEGANT
Shifts A B C G
POST SPG
22.00 22.00
Cheese winding drum set as per TFO set up and
according to shift supervisor instruction.
CHEESE WINDING
& TFO
JOBBER
Activity Description
Come on his duty 30 mins prior to shift timings, take
over the charge
26.55 26.55
Collect all workers' card and adjust all workers as per
supervisor instruction & manage hands shortage.
Give instruction to all winders about running cone
cheese , tfo tip, m/c count and lot.
Systematically adjust all empty and full trolleys
Check cheese winding idle drum and handover a report
to shift supervisor
2
Basic Workload per Shift ( in man minutes)
Remarks:
Random Cheese weight
Note cheese winding doffing time & make production
report
Rewinding 4 cheese and inform related person about
any fault
Check and set cheese winding tension wt.
Check winder no. on cheese and tfo cone
Check hard waste per tenter
Count change slip receive by shift officer and particular
change by maintenance fitter
Bottom material collection and finish with winder help
Alloted m/c cleaning check & approve by shift
supervisor.
Aid 4 knotters in maintenance cleaning
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Work Centre Present Manpower 1 1 1
Designation Proposed Manpower 1 1 1
Sl.
No
Crew
Size
Freq/
Shift
Element
al Time
(Mins)
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 1 10.00 10.00 10.00
2
1 1 10.00 10.00 10.00
3 1 1 8.30 8.30 8.30
4
1
1312
Cones
0.02 26.24 26.24
5
1 21.87 0.57
12.46
12.46
6
1 21.87 1.36
29.74
29.74
7
1 4.37 0.92
4.02
4.02
8
1 20 1.61
32.2
32.20
9
1 1312 0.02 26.24 26.24
10
1 1312 0.05 65.60 65.60
11 1 5 6 30.00 30.00
12 1 2 1 63.00 126.00
A 380.81
B 14
C 434.12
D 450
E 96.5%
F 1
G 96.5%
Section
Ensure and keep all m/c head clean
Elemental time of loading 1 cone to trolley
WLS No: ESP/W/31
WORK LOAD DETAILS SHEET
Elegant Spg.
Shifts A B C G
Post Spg.
TFO
Doff Carrier
Activity Description
Come on his duty 10 mins prior to shift
Check and systematically arrange the
material lotwise in packing & YCS room.
Proposed Utilisation(%)
Remarks:
Elemental time for Marking the Cones with
chalk in packing dept.
Elemental Time for placing the cones
lotwise in the packing area
Cleaning 5 trolleys per shift
Basic Workload per shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Relieve- Two TFO tenter's for breaks
Standard Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per Shift
Movement time propotionate to 1312 times
the cone is fetched
Movement time propotionate to no. of trips
made to carry trolley to packing dept. &
coming back
Movement time propotionate to no. of trips
made to carry trolley to Yarn Conditioning
Room & coming back
Movement Time of carrying empty trolley
from the area where empty trolleys are kept
to the respective m/c for doffing & Vice-a -
versa.
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre
Present
Manpower
8 -
Designation
Proposed
Manpower
8 -
Sl.
No
Crew
Size
Freq/
Shift
No of
machi
ne
Basic
Time
(Mins)
Allow
ance
(%)
Total
Time
(Mins)
1
1 80.0 4 0.0782 13 28.28
2
1 80.0 4 0.5601 13 202.51
3
1 80.0 4 0.0790 13 28.57
4
1 39.8 4 0.0221 13 3.98
5 1 39.8 4 0.0147 13 2.65
6
1 39.8 4 0.2760 13 49.65
7 1 39.8 4 0.0380 13 6.83
8 1 19.9 4 0.4000 13 35.98
9 1 1 1 20.0 13 20.00
A 378.45
B 480
C 78.84%
The running efficiency is arrived by the formula provided in the research paper : The
Efficiency of N machines Uni-Directionally patrolled by single operative by
Mr.C.Mack,T.Murphy and N.L.Webb,Journal of the Royal Statistical Society, (1957).
r = (b-1) / [ gN{K+(b-1)C}]
g - 0.00027794 , N- 624 (4*156), C- 0.4 , K - 0.07
The running efficiency is calculated using the above formula for different number of drums
and tabulated below:
No of Drums
Running Efficiency
() (%)
Operator workload(%)
Basic Workload per Shift ( in man minutes)
Net Available man-mins
Present Utilisation(%)
Attend the thread cut
Clean the machine
Bring empty TFO cone from the cone
room
Keep the cones on the machine
Remove the full TFO cone, place on the
machine holder & keep empty paper
cone & join
Write the number on the paper cone
Activity Description
Bring the cheese winding cone from the
storage area, arrange on the machine
table, keep the empty trolley aside(per
cone)
Replace the empty cheese cone with the
full cheese cone & keep the empty
cheese on the machine table& tie
Collect the empty cheese cone and
arrange it on the rack colourwise
TFO-VJ 8 8
Tenter 8 8
WLS No: ESP/W/32
WORK LOAD DETAILS SHEET
Elegant Spinning
Shifts A B C G
Post Spinning
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre
Present
Manpower
8 -
Designation
Proposed
Manpower
8 -
Sl.
No
Crew
Size
Freq/
Shift
No of
machi
ne
Basic
Time
(Mins)
Allow
ance
(%)
Total
Time
(Mins)
Activity Description
TFO-VJ 8 8
Tenter 8 8
WLS No: ESP/W/32
WORK LOAD DETAILS SHEET
Elegant Spinning
Shifts A B C G
Post Spinning
The above values are depicted in the graph to findout the optimum (where running efficiency
& operative workload meets) number of drums to be alloted per personnel and presented
below:
From the graph, the optimum number of drums to be alloted per operator is 702 drums(4.5
machines).As it is difficult to breaks into half machine, it is recommended to assign four
machine per operator, keeping in view of machine utilisation.
Remarks:
Collection of full TFO cones from machine table to trolley is performed by doffers
Machine Efficiency: (Sample calculation)
Machine available hours * (Time lost due to general cleaning,count/lot change,idle and
maintenance cleaning,breakdown) = Machine running hours ( 8 hours * 98.5 % = 7.88 hours)
858 (5.5*156) 91.79% 106.85%
780 (5*156) 92.48% 97.51%
702 (4.5*156) 93.18% 88.18%
624 (4*156) 94.05% 78.84%
624
(4*15
6)
702
(4.5*1
56)
780
(5*15
6)
858
(5.5*1
56)
Running Efficiency
() (%)
94.05% 93.18% 92.48% 91.79%
Operator
workload(%)
78.84% 88.18% 97.51% 106.85%
0.00%
20.00%
40.00%
60.00%
80.00%
100.00%
120.00%
E
f
f
i
c
i
e
n
c
y
(
%
)
TFO-Tenter
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre
Present
Manpower
8 -
Designation
Proposed
Manpower
8 -
Sl.
No
Crew
Size
Freq/
Shift
No of
machi
ne
Basic
Time
(Mins)
Allow
ance
(%)
Total
Time
(Mins)
Activity Description
TFO-VJ 8 8
Tenter 8 8
WLS No: ESP/W/32
WORK LOAD DETAILS SHEET
Elegant Spinning
Shifts A B C G
Post Spinning
* Time lost due to general cleaning,count/lot change,idle and maintenance cleaning,breakdown is
collected from the management
Actual Machine efficiency (%)=Machine Running hours* Running efficiency
EX: For 624 spindles, Actual machine efficiency (%) = 7.88 hours *0.9405 = 7.411 hours/shift
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 1 1 1 -
Designation Proposed Manpower 1 1 1 -
Sl.
No
Crew
Size
Freq /
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 6 63 378.00
2
1 1 10.00 10.00
3
A 388.00
B 13
C 438.44
D 450
E 97.43%
F 1
G 97.43%
WLS No: ESP/W/33
WORK LOAD DETAILS SHEET
Elegant Spinning
Shifts A B C G
TFO
Reliever-Tenter
Activity Description
Relieve- Six TFO tenter's for breaks
Post Spinning
Collect the hardwaste and handover&inform to
supervisor
Perform the activities scheduled by supervisor/jobber
like assisting the tenter where two machine open at a
time , shift second quality cone to respective
area,single &fatta tar cheese creel in TFO,etc
Proposed Utilisation(%)
Remarks:
Lunch-30 mins, Tea - 10 mins, Personal Intervention(5%) - 23 mins . Total - 63
mins/shift/person
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 1 1 1 -
Designation Proposed Manpower 1 1 1 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 1 10.00 10.00
2 1 2 24.00 24.00
3 1 5 325.00 325.00
4 1 1 20.00 20.00
A 379.00
B 13
C 428.27
D 450
E 95.17%
F 1
G 95.17%
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Net Available man-mins
Proposed Manpower per shift
Proposed Utilisation(%)
Remarks:
Present Utilisation(%)
TFO
FLOOR CLEANER
Activity Description
Take charge of his duty
Check and do TFO overhead dust box cleaning.
Do sweeping and collect hard waste
Dispose scrap in scrap yard
WLS No: ESP/W/34
WORK LOAD DETAILS SHEET
ELEGANT
Shifts A B C G
POST SPG
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 1
Designation Proposed Manpower - - - 1
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
1 4 57.76 231.04
2
1 16 0.96 15.36
3 1 16 2.00 32.00
A 278.40
B 13
C 314.59
D 480
E 65.54%
F 1
G 65.54%
WLS No: ESP/W/35
WORK LOAD DETAILS SHEET
Elegant Spinning
Shifts A B C G
Elegant Walk Path
Floor Cleaner
Activity Description
Clean the pathway using floor cleaning machine(from
Blowroom to TFO)
Post Spining
Drain the used water in the drain
Fill the water in the machine
Proposed Utilisation(%)
Remarks:
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
2.0 A ELEGANT SPINNING - MECHANICAL
MAINTENANCE
________________________________________________________________________________________
National Productivity Council, Bangalore.
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____________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
2.0 A
2.1
I II III G T I II III G T
Fitter - - - 1 1 - - - 1 1
Cleaner - - - 1 1 - - - 1 1
Sr. Fitter - - - 2 2 - - - 2 2
Cleaner - - - 2 2 - - - 2 2
Jr.Fitter 1 1 1 - 3 1 1 1 - 3
Sr. Fitter - - - 1 1 - - - 1 1
Jr.Fitter - - - 1 1 - - - 1 1
Cleaner - - - 1 1 - - - 1 1
Sr. Fitter - - - 1 1 - - - 1 1 Buffing Room
Fitter - - - 1 1 - - - 1 1
Jr.Fitter - - - 1 1 - - - 1 1
Cleaner - - - 7 7 - - - 7 7 Cleaning Gang
Running Fitter 1 1 1 - 3 1 1 1 - 3
Sr. Fitter - - - 1 1
Fitter - - - 1 1
Jr.Fitter - - - 2 2 - - - 2 2
Cleaner - - - 1 1 - - - 1 1
Sr. Learner - - - 1 1 - - - 1 1
2 2 2 25 31 2 2 2 24 30 Total
1 1 - - -
TFO
Autoconer&Cheese
Winding
Ring Frame 4
Main Gang
Blow Room
D/F & Simplex
Post Spinning
1
3
5
Carding 2
ELEGANT SPINNING - MECHANICAL MAINTENANCE
Manpower Deployment
S. No Section / Work area Designation
Present Manpower Proposed Manpower
Remarks
_______________________________________________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
2.0 A
2.2
2.2.1
a)
b)
c)
d)
e)
f)
-
-
-
-
-
-
-
-
-
-
g)
The manpower has been computed with a loading factor of 80 % for the maintenance personnel.
The 80 % loading has been considered to take into account the following:
Bring tools/materials from store Ex: oil,grease,waste cloth, new parts
Breakdown maintenance (Carding, Ringframe & Autowinding) data has been obtained for a
period of two months and the same has been extrapolated for a month.
Running maintenance data has been collected by detailed discussions with the incumbents and
the supervisory personnel and compared with check studies and estimated.
The sum of the preventive maintenance, breakdown maintenance(if any) and running
maintenance (if any) workload for the month gives us the total workload for the mechanical
personnel.
Rest & Relaxation allowance is already included as a part of activity time and presented against
the respective activities.
Prepare attendance
Write logbook
Arranging of tools & parts in tool room
Efforts variation required
Clean the tool room daily morning
The detailed time and motion study is recommended to arrive the standard time for the
activities,whatever timings considered here,based on the group utilisation technique.And cannot
taken for fixing standard times.
ELEGANT SPINNING - MECHANICAL MAINTENANCE
Proposed Changes & Observations
Methodology
Waiting for the machine for maintenance
The preventive maintenance data was collected for all the category of machines. Check studies
on a sample basis were carried out to ascertain the process being followed for the preventive
maintenance. The data gathered during check studies has been applied to the remaining
preventive maintenance activities in that section.
PF - Permanent Fitter(Sr.Fitter,Fitter,Jr.Fitter)
PH - Permanenent Helper/Cleaner
Discard the waste cloth to the waste area daily after maintenance work
Unavoidable delay. Ex: New activity cannot start after 4.30 pm as only 30 mins left for that day
Change dress
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
2.0 A
2.2
ELEGANT SPINNING - MECHANICAL MAINTENANCE
Proposed Changes & Observations
2.2.2
I
a)
b)
2.2.3
a)
b)
c)
It is observed during the study that before all mechanical personnel arrived , the machine was
stopped for scheduled maintenance. Scheduled maintenance activity is started with few
personnel, then one by one joining the workplace. In Ringframe, Machine cleaning is carried out
by six personnel and each have their specific 96 spindle area to be cleaned. In this situation,
three helpers starts the activity early and finishes earlier, whereas the persons joined later
finishes their portion of 96 spindles later. Total machine stopped hour for maintenance
elongates because of this mismatch.
Total Time provided for Scheduled Maintenance
The time provided for scheduled maintenance activities are based on the company
experience/estimation. However, it was observed during the study that the actual time required
for the scheduled maintenance activities are less. So , it is recommended to go for in-depth time
and motion study and fix standards for the regular maintenance activities. This will help in
increasing the availability time of machine and also reduce maintenance personnel workload
further.
Autoconer & Cheesewinding
In view of low utilisation Fitters(38.41%) , it is recommended to deploy one fitter instead of the
present two fitter.
Proposed Changes
Scheduling & Planning
The activities to be so planned and performed that the time taken is minimized. Activities that
can be carried out in parallel have to be planned. It is observed in ringframe that maintenance
personnel, going to bring grease gun, gear box oil and parts to be changed. If the schedule
contain gearbox oil change, while coming itself it could have brought in the trolley.
Observations
During autoconer / cheese winding machine prevent maintenance activity, the respective
machine production operator is forced to idle. It is suggested that the production operator also
assist mechanical team while scheduled maintenance activities like cleaning with compressed
air, cloth for which no special mechanical skill required. Thereby, manpower further could be
reduced. It also helps in building sense of ownership.
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
2.0 A
2.3
S.No
1
2
3
4
5
6
7
8
9
Autowinding&Cheese
winding
EMS/W/08
TFO EMS/W/09
Blowroom &Carding-
Running Fitter
EMS/W/03
Drawframe&Simplex EMS/W/04
Ring Frame-Running
Fitter
EMS/W/07
Ring frame-Cleaning EMS/W/05
Ring frame-Main Gang EMS/W/06
Blowroom EMS/W/01
Carding EMS/W/02
ELEGANT SPINNING - MECHANICAL MAINTENANCE
Workload Sheets Summary
Area of work WLS Number
________________________________________________________________________________________
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_____________________________________________________________________________________________________________________________________________________
_
Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
ELEGANT
SPG
A B C G
Section Mechanical - - - 1F+1 H
Work Centre
Blowroom &
Mixing
- - - 1F+1 H
PF PH PF PH
1
Line Blender clg. 2 1 1 2.988 3 18 18
2 Hopper Feeder clg. 2 1 1 1.992 3 12 12
3 Conden. & Doffing Section Clg. 2 1 1 1.992 3 12 12
4
Scutcher Cleaning 3 1 1 2.988 3 27 27
5
Mixing Blender clg 2 1 1 2.988 3 18 18
6
Mixing Condenser cleaning 1 1 1
1.992
7 14 14
7 Gear Box/Shell Roll Checking 1/3 1 1 1.992 6 4 4
8
K. Beater Legs Change 1/9 1 1 3.984 3 1 1
9
V.F.O.Wire Change 1/12 1 1 5.976 1 0 0
10
Beater Cleaning by Petrol 26 1
0.996 1 0 26
11 Compactor Cleaning 26 1 0.05 1 0 1
12 Grid Bar Cleaning 4 1 1 1.992 1 8 8
13
Primary Filter Cloth Washing 4 1 1
0.996 1 4 4
14
Secondary Filter Cleaning 4 1 1
1.992 1 8 8
15
Running Problems(During General Shift) 26 1
1 1 26
A 152.33 153.52
B 166.4 166.4
C 91.54% 92.26%
D 1 1
E 91.54% 92.26%
WLS No:EMS/W/01
WORK LOAD DETAILS SHEET
Shifts
Present Manpower
Proposed Manpower
Net Available man-hours per month(8*26*80% = 166.4 hours)
Present Utilisation(%)
Proposed Manpower
Proposed Utilisation(%)
Monthly
workload(Hours)
Total Workload per month ( in man hours )
S.
No
Activity Description
Frequency/
Month
Crew Category Time
(in Hours)
No of
Machine
_____________________________________________________________________________________________________________________________________________________
______ National Productivity Council, Bangalore.
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_____________________________________________________________________________________________________________________________________________________
_
Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
PF PH PF PH
Monthly
workload(Hours)
S.
No
Activity Description
Frequency/
Month
Crew Category Time
(in Hours)
No of
Machine
_____________________________________________________________________________________________________________________________________________________
______ National Productivity Council, Bangalore.
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________________________________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
ELEGANT
SPG
A B C G
Section Mechanical - - - 2F+2H
Work Centre Carding - - - 2F+2H
PF PH PF PH
1 Full Setting 2 2 1 2.7 22 239.08 119.54
2 Cyl Wire Change 1/24 1 2 14.5 22 13.28 26.56
3 Doffer Wire Change 1/24 1 2 14.5 22 13.28 26.56
4 Flat Tops Change 1/30 1 2 5.4 22 3.98 7.97
5 Stn Flats(Back) Change 1/9 1 2 1.8 22 4.43 8.85
6
Stn Flats(Front) Change 1/15 1 2 1.8 22 2.66 5.31
7 Lic-in Wire Change 1/6 1 2 0.9 22 3.32 6.64
8 Cyl. & Doffer Wire Grinding 1/6 1 2 0.9 22 3.32 6.64
9 Coiler Overhauling 1/18 2 1 3.6 22 8.85 4.43
10 Clearer roller Clothing Change 1/12 1 1 0.5 22 0.83 0.83
Daily Works
11 CTC Cleaning 26 0 2 0.03 12 0.00 20.80
12 Stripping Brush Cleaning 26 1 0.025 12 0.00 7.80
13 Regular checkup and fill the log book 26 1 0.12 1 3.03 0.00
A 296.07 241.94
B 166.4 166.4
C 88.96% 72.70%
D 2 2
E 88.96% 72.70%
Total Workload per month ( in man hours )
Net Available man-hours per month(8*26*80% = 166.4 hours)
Running fitter in the carding section, performs the CTC cleaning with the general shift maintenance personnel at the general shift starting.
S.
No
Activity Description
Frequency/
Month
Crew Category
Present Utilisation(%)
Proposed Manpower
Proposed Utilisation(%)
Proposed
Manpower
Monthly workload(Hours) Time
(in Hours)
No of
Machine
WLS No:EMS/W/02
WORK LOAD DETAILS SHEET
Shifts
Present
Manpower
_________________________________________________________________________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre
Present
Manpower
1 1 1 -
Designation
Proposed
Manpower
1 1 1 -
Sl. No
Crew
Size
Freq/
Shift
Basic
Time
(mins)
Total
Workload
(mins)
1 1 8 3.00 24.00
2 1 8 2.45 19.60
3 1 4 7.04 28.16
4 1 1 3.00 3.00
5 1 1 2.06 2.06
6 1 1 25.00 25.00
7 1 1 20.00 20.00
8 1 1/3 20.00 6.67
9 108.00
A 212.49
B 450.0
E 47.22%
F 1
G 47.22%
Date Shift
No of
problems
Total
Time
(Mins)
03-Jan A 5 75
04-Jan A 3 35
08-Jan A 6 120
05-Jan C 5 100
09-Jan B 10 190
12-Jan C 7 105
13-Jan B 6 105
10-Jan A 6 65
06-Jan C 10 210
11-Jan B 6 120
64 1125
Lot change cylinder side checking
K-beater & MBO beater cleaning
Total Workload per shift ( in man mins )
Net Available man-mins per month
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
To assess the amount of time spent on attending running problems, the random samples shifts is
selected from the past log books(Jan-2012). The random number is generated and number of
problems attended and time spent for the problem is tabulated as follows:
Total
C G
Mechanical
Clean the primary ( 2nos)
Check the card speed, sliver weight, limit
switch of all card(22 nos)
Remarks:
Attend running breakdown(24% * 450mins =
108 mins/shift)
Write log book
Front side bottom jam
CTC Cleaning(help the general shift gang),Flat
brush cleaning
Blowroom & Carding
Running Fitter
Activity Description
Clean the Compactor
WLS No: EMS/W/03
WORK LOAD DETAILS SHEET
Elegant Spg
Shifts A B
_____________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre
Present
Manpower
1 1 1 -
Designation
Proposed
Manpower
1 1 1 -
Sl. No
Crew
Size
Freq/
Shift
Basic
Time
(mins)
Total
Workload
(mins)
C G
Mechanical
Blowroom & Carding
Running Fitter
Activity Description
WLS No: EMS/W/03
WORK LOAD DETAILS SHEET
Elegant Spg
Shifts A B
The average time to resolve a complaint works out to be 17.57 minutes.(1125/64)
The average arrival rate is 64/10 = 6.4 per shift and the average servicing rate = 8*60 /17.57
= 27.31 per shift
/ = 0.2343= 24 %
_____________________________________________________________________________________________
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________________________________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
ELEGANT
SPG
A B C G
Section Mechanical - - - 2F+1H
Work Centre
Drawframe
&Simplex
- - - 2F+1H
PF PH PF PH
A Draw Frame
1 Machine Clg. Of Cherry Hara 3 2 1 1.489 2 17.9 8.9
2 Machine Clg. Of LDO/6 2 2 1 2.978 4 47.6 23.8
3 Cots Buffing 1 1 1 2.978 6 17.9 17.9
4 Oil Change 1/4 1 1 0.5 6 0.8 0.8
5 Basic Gauge Setting 1/6 2 1 5.956 6 11.9 6.0
6 Coiler O.H 1/6 2 1 8.934 6 17.9 8.9
7 Gear Box O.H 1/12 2 1 8.934 6 8.9 4.5
B Simplex
1 M/C Cleaning 1 1/2
2 Bottom Apron Change 1
3 Top Apron Change 1
4 Gear Box Oil Change 1/4
5 Reducer Gear Box Oil Change 1/2
6 Cots Buffing 1/2 1 1 2.978 5 7.4 7.4
7 New Cots Change 1/18 1 1 5.956 5 1.7 1.7
Time
(in Hours)
No of
Machine
Monthly workload(Hours) S.
No
Activity Description
Frequency/
Month
2 1 4.467 5
WLS No:EMS/W/04
WORK LOAD DETAILS SHEET
Shifts
Present Manpower
67.01 33.50
Crew Category
Proposed Manpower
__________________________________________________________________________________________________________________________________________________________
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________________________________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
ELEGANT
SPG
A B C G
Section Mechanical - - - 2F+1H
Work Centre
Drawframe
&Simplex
- - - 2F+1H
PF PH PF PH
Time
(in Hours)
No of
Machine
Monthly workload(Hours) S.
No
Activity Description
Frequency/
Month
WLS No:EMS/W/04
WORK LOAD DETAILS SHEET
Shifts
Present Manpower
Crew Category
Proposed Manpower
8 Top & Bottom Apron Cleaning 1/3 1 1 2.978 5 5.0 5.0
9 Spindle Truing 1/4 2 1 8.934 5 22.3 11.2
10 Bottom Roll Truing 1/6 2 1 8.934 5 14.9 7.4
11 Arbour Greasing 1/6 1 1 2.978 5 2.5 2.5
12 Bottom & Top Clearer Cloth Change 1/12 2 1 8.934 5 7.4 3.7
13 Pressure Finger Change 1/24 2 1 11.912 5 5.0 2.5
C Daily
1
Top Roller, Coiler & Clearer Cloth Cleaning-
D/F 26 1 1.07 6 27.73 0.00
2 D/F Creel Cleaning 26 1 0.25 6 0.00 6.50
3
Head Stock Cleaning, Chalk powder applied -
Simplex,D/F
26 1 0.42 5 0.00 10.83
4
Check both D/F,Simplex machine. Fill the log
book
26 1 0.50 13.00 0.00
5 Liquimix to Cots 26 1 0.25 6.50 0.00
6 Running Problems 26 1 1 26.00
A 329.26 162.93
B 166.4 166.4
C 98.94% 97.91%
D 2 1
E 98.94% 97.91%
Total Workload per month ( in man hours )
Remarks
Proposed Utilisation(%)
Proposed Manpower
Present Utilisation(%)
Net Available man-hours per month(8*26*80% = 166.4 hours)
__________________________________________________________________________________________________________________________________________________________
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________________________________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department ELEGANT SPG A B C G
Section Mechanical - - - 1F+6H
Work Centre Ringframe - - - 1F+6H
PF PH PF PH
A Ringframe
1 M/C Cleaning 1
2 Cots Change 1/9
3 Top Apron Change 1/24
4 Separator Washing 1/9 1 6 3.00 26 8.67 52.00
5 Top Apron Washing 1/6 0 2 3.00 26 0.00 26.00
6 Spindle Oil Change 1/9 1 1 3.00 26 8.67 8.67
7 Bottom Apron Change 1/9 0 4 1.50 26 0.00 17.33
8
Suction Tube Washing 1/6 0 4 1.50 26 0.00 26.00
9 Arbour Greasing 1/9 1 1 3.00 26 8.67 8.67
10 Semi Over Hauling 1/30 3* 9** 27.00 26 0.00 138.68
B TFO
1 Machine Cleaning 1
2 Centering Disc Cleaning & Greasing 1/2
3 Thread Guide Washing 1/3
4 Main Drive Shaft Bearing Greasing 1/3
5 Spindle Oil Topping 1/3 1 1 0.32 32 3.40 3.40
6 Spindle Oil Change 1/9 1 1 0.32 32 1.13 1.13
7 Variator Assly Washing 1/6 0 2 2.55 32 0.00 27.18
C Cheesewinding
1
Machine Cleaning 1 1 6 1.91 5 9.56 57.33
Monthly
workload(Hours)
1
WLS No:EMS/W/05
WORK LOAD DETAILS SHEET
Shifts
Present
Manpower
Proposed
Manpower
6
S.
No
Activity Description
Frequency/
Month
Crew Category
1.5 26
Time
(in Hours)
No of
Machine
39 234
6 40.77 1 1.274 32 244.61
__________________________________________________________________________________________________________________________________________________________
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________________________________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department ELEGANT SPG A B C G
Section Mechanical - - - 1F+6H
Work Centre Ringframe - - - 1F+6H
PF PH PF PH
Monthly
workload(Hours)
WLS No:EMS/W/05
WORK LOAD DETAILS SHEET
Shifts
Present
Manpower
Proposed
Manpower
S.
No
Activity Description
Frequency/
Month
Crew Category Time
(in Hours)
No of
Machine
2 Drum Polishing 1 1 1 2.55 5 12.74 12.74
A 132.59 857.74
B 166.4 166.4
C 79.68% 85.91%
D 1 6
E 79.68% 85.91%
Proposed Manpower
Total Workload per month ( in man hours )
Net Available man-hours per month(8*26*80% = 166.4 hours)
Present Utilisation(%)
* from main gang
** two from main gang
Proposed Utilisation(%)
Remarks
__________________________________________________________________________________________________________________________________________________________
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_________________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department ELEGANT SPG A B C G
Section Mechanical - - - 1F+1 Jr.F
Work Centre Ringframe - - - 1F+1Jr.F
F Jr.F F Jr.F
A Ringframe
M/C Cleaning 1
Cots Change 1/9
Top Apron Change 1/24
Separator Washing 1/9
Top Apron Washing 1/6
Bottom Apron Change 1/9
Spindle Oil Change 1/9
Suction Tube Washing 1/6
Arbor Greasing 1/9
1 Drum Shaft Bearing Greasing 1/3 1 1
2 Variator Checking 1/3 1 0
3
C1, C2 Setting 1/3 2 0
4 Bottom Apron Setting 1/3 2 0
5 Fly Catcher setting 1/3 1 1
6 Bottom Roller Greasing 1/3 1 1
7 Delay Draft Checking 1/3 2 0
8 Drum Filter Cloth Wash 1/6 0 1
Proposed
Manpower
0.800 26
WLS No:EMS/W/06
WORK LOAD DETAILS SHEET
Shifts
Present Manpower
R/F Cleaning Gang
6.93 6.93
S.
No
Activity Description
Frequency/
Month
Crew Category Time
(in Hours)
No of
Machine
Monthly
workload(Hours)
________________________________________________________________________________________________________________________________________
National Productivity Council, Bangalore.
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_________________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department ELEGANT SPG A B C G
Section Mechanical - - - 1F+1 Jr.F
Work Centre Ringframe - - - 1F+1Jr.F
F Jr.F F Jr.F
Proposed
Manpower
WLS No:EMS/W/06
WORK LOAD DETAILS SHEET
Shifts
Present Manpower
S.
No
Activity Description
Frequency/
Month
Crew Category Time
(in Hours)
No of
Machine
Monthly
workload(Hours)
9
Jockey Pulley Greasing 1/9 1 1 1.60 26 5 5
10 Gear Box Oil Changing 1/6 1 1 0.80 26 3 3
11 Spindle Gauge 1/9 3 1 3.20 26 28 9
12
Ring Change 1/48 3 4.80 26 8 0
13 Lappet Hook Change 1/48 3 0.80 26 1 0
14 Spindle Tape change 1/24 2 2 3.20 26 7 7
15 Top Clearer Cloth Changing 1/24 2 2 9.60 26 21 21
16 Bottom Roller Truing 1/9 3 1 4.80 26 42 14
17 Semi Over Hauling 1/30 3 9* 14.40 26 33 22
A 154.14 87.83
B 166.4 166.4
C 92.63% 52.78%
D 1 1
E 92.63% 52.78%
Proposed Manpower
Total Workload per month ( in man hours )
Proposed Utilisation(%)
Remarks:
Net Available man-hours per month(8*26*80% = 166.4 hours)
Present Utilisation(%)
* 7 personnel from cleaning gang
________________________________________________________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 1 1 1 -
Designation Proposed Manpower 1 1 1 -
Sl. No
Crew
Size
Freq/
Shift
Basic
Time
(mins)
Total
Workload
(mins)
A
1 1 1 20.00 20.00
2 1 1 1/45 30.00 30.67
3 1 2/9 33.16 7.37
4 1 2/9 13.37 2.97
5 1 16/45 15.00 5.33
6 1 1 30.00 30.00
7 1 1 32.00 32.00
8 1 1 20.00 20.00
9 1 1 30.00 30.00
10 1 1 15.00 15.00
11 1 1 30.00 30.00
12 1 1 30.00 30.00
B
1 1 7/15 30.00 14.00
2 1 1/15 30.00 2.00
3 1 1/5 25.00 5.00
C 126.00
A 400.34
B 450.0
E 88.96%
F 1
G 88.96%
Remarks:
Count change depend on the count. For calculation it has taken maximum time
To assess the amount of time spent on attending running problems, the random samples shifts is
selected from the past log books(Jan-2012). The random number is generated and number of
problems attended and time spent for the problem is tabulated as follows:
Attend running breakdown(28% * 450mins = 126
mins/shift)
Total Workload per shift( in man mins)
Net Available man-mins per shift
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
TPI Change
Running Fitter
Activity Description
Go round to check the problem in ring frame
machine. Check spindle tape, bottom apron and
other idle spindle, Drum checking, Spindle speed
OHTC cleaning(13 OHTC/shift)
Ringframe
Cots Checking(8 machines/shift)
TFO
Count change
RT/NT Change
Mechanical
Check the needle bearing(8 machine/shift)
Drum pulley shaft cleaning(8 machines/shift)
Check the drum(26 machine/shift)
Count change
Ringframe&TFO
Change from NT to RT
Change the jockey pulley cover in reverse direction
TPI Change
Head Stock cleaning
Draft cleaning
WLS No: EMS/W/07
WORK LOAD DETAILS SHEET
Elegant Spg
Shifts A B C G
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 1 1 1 -
Designation Proposed Manpower 1 1 1 -
Sl. No
Crew
Size
Freq/
Shift
Basic
Time
(mins)
Total
Workload
(mins)
Running Fitter
Activity Description
Mechanical
Ringframe&TFO
WLS No: EMS/W/07
WORK LOAD DETAILS SHEET
Elegant Spg
Shifts A B C G
Shift
Total
Time(Min
s)
A 170
A 110
B 155
C 200
B 80
C 165
B 205
A 115
C 50
B 100
1350 Total
13-Jan
Date
06-Jan
07-Jan
08-Jan
10-Jan
The average arrival rate is 74/10 = 7.4 per shift and the average servicing rate = 8*60 /17.57 =
26.31 per shift
03-Jan
The average time to resolve a complaint works out to be 18.24 minutes.
11-Jan
12-Jan
/ = 0.2812= 28 %
11
5
8
3
04-Jan
01-Jan
10
4
8
74
No of problems
8
7
10
________________________________________________________________________________________
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__________________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department ELEGANT SPG A B C G
Section Mechanical - - - 2F+2H
Work Centre
Autoconer&
Cheese winding
- - - 1F+2H
PF PH PF PH
A Autoconer
1 Machine Cleaning 1
2
Bearing Centre Sleeve Silicon Oiling 1
3
Impeller and Wire Mesh Cleaning & Checking 1
4 Drum Polishing 1
5 Suction Fan Bearing Greasing 1/2
6 Magazine Assly. Cleaning & Resetting 1/12 2 1 1.88 7 2.19 1.10
7 Cam Drive Shaft Bearing Greasing 1/3 1 1 1.00 7 2.33 2.33
8 Auto Doffer Cleaning & Lubrication 1/2 1 1 1.00 7 3.50 3.50
9 Over Head Unit Cleaning & Checking 1/3 1 1 1.00 7 2.33 2.33
10
Spindle Unit Opening Cleaning & Checking 1/9 1 1 4.00 7 3.11 3.11
11
Tension Assly & Shutter Cutter Opening & Clg. 1/6 3 1 4.00 7 14.00 4.67
12 Bearing Centre Greasing RH (Base) & LH (Nose) 1/10 1 1 4.00 7 2.80 2.80
13 Splicing Head Servicing 1/6 3 1 6.00 7 21.00 7.00
B Cheesewinding
1
Machine Cleaning 1
2 4
R/F Cleaning Gang
2.00 7 8.06
Time
(in Hours)
No of
Machine
Frequency/
Month
Crew Category
Monthly
workload(Hours)
56.00
WLS No:EMS/W/08
WORK LOAD DETAILS SHEET
Shifts
Present
Manpower
Proposed
Manpower
S.
No
Activity Description
______________________________________________________________________________________________________________________________________
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__________________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department ELEGANT SPG A B C G
Section Mechanical - - - 2F+2H
Work Centre
Autoconer&
Cheese winding
- - - 1F+2H
PF PH PF PH
Time
(in Hours)
No of
Machine
Frequency/
Month
Crew Category
Monthly
workload(Hours)
WLS No:EMS/W/08
WORK LOAD DETAILS SHEET
Shifts
Present
Manpower
Proposed
Manpower
S.
No
Activity Description
2 Drum Polishing 1
3
Pivot Bearing Oiling 1/6 1 1 0.50 5 0.42 0.42
4 Cradle Setting 1/6 1 1 2.00 5 1.67 1.67
5
Upper & Lower Guide Pulley Brg. Oiling 1/6 1 1 2.00 5 1.67 1.67
6
Upper, Lower pulley Setting 1/6 1 1 2.00 5 1.67 1.67
7
Tension Assly. & Cone Peg Setting 1/6 1 1 2.00 5 1.67 1.67
8 S.M.Ceramic Guide Setting 1/6 1 1 1.00 5 0.83 0.83
9 Tension Disc Cleaning 1/6 1 1 0.50 5 0.42 0.42
10
Over Head Blower O.H. 1/12 1 1 2.00 5 0.83 0.83
11
Gear Box Oil Change 1/12 1 1 5.00 2 0.83 0.83
Daily
12 Splicing Checking 26 1 0.0042 60 6.50 0.00
13 Cheese winding Drum Spray 4 1 0.0029 60 0.00 0.70
14 Auto Coner Bobbin Conveyor Belt Clg. 26 1 0.036 7 0.00 6.50
15 Autoconer Over Head Cleaning
16 1 Magitec 26 1 0.10 1 0.00 2.50
R/F Cleaning Gang
______________________________________________________________________________________________________________________________________
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__________________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department ELEGANT SPG A B C G
Section Mechanical - - - 2F+2H
Work Centre
Autoconer&
Cheese winding
- - - 1F+2H
PF PH PF PH
Time
(in Hours)
No of
Machine
Frequency/
Month
Crew Category
Monthly
workload(Hours)
WLS No:EMS/W/08
WORK LOAD DETAILS SHEET
Shifts
Present
Manpower
Proposed
Manpower
S.
No
Activity Description
17 6 Pneumafil 26 1 0.06 6 0.00 9.78
18 Cheesewinding Over Head Cleaning
19 3 RJK 26 1 0.056 3 0.00 4.39
20 2 SSM 26 1 0.032 2 0.00 1.65
21 Go round and attend the idle spindle, Running 26 1 2.000 52.00 0.00
A 127.83 116.71
B 166.4 166.4
C 38.41% 35.07%
D 1 2
E 76.82% 35.07%
Total Workload per month ( in man hours )
In view of low utilisation of helpers(35.07%), it is recommended to provide two helpers. This has been done mainly to reduce machine down time for
the scheduled maintenance activity. Two helpers involved mainly in machine cleaning, where full autoconer machine is stopped. For the fitter activities
like Tension Assly & Shutter Cutter Opening & Clg (only twelve drums stops at a time), one fitter and two helpers are proposed.
Present Utilisation(%)
Proposed Manpower
Proposed Utilisation(%)
PH- In autowinding includes Jr Fitter & helper.
Cheese winding Machine cleaning&drum polishing activities are performed by Ring frame machine cleaning gang. It is considered under their
workload sheet.
Net Available man-hours per month(8*26*80% = 166.4 hours)
______________________________________________________________________________________________________________________________________
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____________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
ELEGANT
SPG
A B C G
Section Mechanical - - - 1F+1H
Work Centre TFO - - - 1F+1H
PF PH PF PH
Machine Cleaning 1
Centring Disc Cleaning & Greasing 1/2
Spindle Oil Topping 1/3
Spindle Oil Change 1/9
Thread Guide Washing 1/3
Variator Assly Washing 1/6
Main Drive Shaft Bearing Greasing 1/3
1
Machine Cleaning-Checking of Machine
from TFO Side
1 1 0 0.69 32 21.95 0.00
2
Brake Roller Oiling 1/3 1 1 0.4262 32 4.55 4.55
3 All Gearing & Cam Box Checking 1/3 1 1 0.8524 32 9.09 9.09
4 Gear Shaft Bearing Greasing 1/4 1 1 0.8524 32 6.82 6.82
5
Take-Up & PTR Shaft Bearing Greasing 1/6 1 1 0.8524 32 4.55 4.55
6 Spindle Brg Greasing 1/6 1 1 0.8524 32 4.55 4.55
7 PTR to Pigtail Setting 1/6 1 1 1.7048 32 9.09 9.09
WLS No:EMS/W/09
WORK LOAD DETAILS SHEET
Shifts
Present
Manpower
Monthly
workload(Hours)
R/F Cleaning Gang
Proposed
Manpower
S.
No
Activity Description
Frequency/
Month
Time
(in Hours)
No of
Machin
e
Crew Category
_______________________________________________________________________________________________________________________________
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Department
ELEGANT
SPG
A B C G
Section Mechanical - - - 1F+1H
Work Centre TFO - - - 1F+1H
PF PH PF PH
WLS No:EMS/W/09
WORK LOAD DETAILS SHEET
Shifts
Present
Manpower
Monthly
workload(Hours)
Proposed
Manpower
S.
No
Activity Description
Frequency/
Month
Time
(in Hours)
No of
Machin
e
Crew Category
8 Cradle Setting Checking 1/6 1 1 0.8524 32 4.55 4.55
9 Thread guide setting 1/6 1 1 0.8524 32 4.55 4.55
10
CLM and Drop Wire Setting Checking 1/6 1 1 0.8524 32 4.55 4.55
11 Jockey Pulley Greasing 1/9 1 1 0.8524 32 3.03 3.03
12
Gearing OverHauling 1/18 1 1 1.7048 32 3.03 3.03
13 Gear Box Oil Change 1/18 1 1 0.8524 32 1.52 1.52
14 Over Head OverHauling 1/18 1 1 0.8524 13 0.62 0.62
Daily
15 T.F.O. Over Head Cleaning(Elgi Jacobi-
12,Nugen-1no)Remove the waste, clean
with broom stick
26 1 0.06 13 0 19.25
16 Go round the all TFO machine,notedown the
problem in the log book
26*2 times
per day
1 0.67 32 35 0
_______________________________________________________________________________________________________________________________
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____________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
ELEGANT
SPG
A B C G
Section Mechanical - - - 1F+1H
Work Centre TFO - - - 1F+1H
PF PH PF PH
WLS No:EMS/W/09
WORK LOAD DETAILS SHEET
Shifts
Present
Manpower
Monthly
workload(Hours)
Proposed
Manpower
S.
No
Activity Description
Frequency/
Month
Time
(in Hours)
No of
Machin
e
Crew Category
17 Attend th running problem identifed during
intial round
26 1 1 1 1 26 26.0
18 Count Change
13 1 0.5 1 7 0
A 149.93 105.73
B 166.4 166.4
C 90.10% 31.77%
D 1 1
E 90.10% 63.54%
Present Utilisation(%)
Proposed Manpower
Proposed Utilisation(%)
Net Available man-hours per month(8*26*80% = 166.4 hours)
Total Workload per month ( in man hours )
_______________________________________________________________________________________________________________________________
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___________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
2.0 B ELEGANT SPINNING - ELECTRICAL
MAINTENANCE
________________________________________________________________________________
National Productivity Council, Bangalore.
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_________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
2.0 B
2.1
I II III G T I II III G T
1 Shift Maintenance Electrician
1 1 1 - 3 1 1 1 - 3
2 General Shift maintenance - Attending to all
Electronic break down of machine &
maintain the parameter. Perform PM as per
the schedule
Electronic Tech.
- - 1 1 2 - - 1 1 2
3 Humidity plant Humidity
attendant
1 1 1 - 3 1 1 1 - 3
4 General shift maintenance - Perform
machine PM, Attend to the shift break down
Electrician
- - - 2 2 - - - 2 2
5 Motor maintenance Motor Fitter
- - - 1 1 - - - 1 1
6 H.Plant & Air compressor U/Fitter
- - - 1 1 - - - 1 1
7 Trench Cleaning Trench Cleaner
- - - 2 2 - - - 2 2
2 2 3 7 14 2 2 3 7 14
Proposed Manpower
Remarks
Total
ELEGANT SPINNING - ELECTRICAL MAINTENANCE
Manpower Deployment
S. No Section / Work area Designation
Present Manpower
___________________________________________________________________________________________________________________
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___________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
2.0 B
2.2
1 No changes proposed.
ELEGANT SPINNING - ELECTRICAL MAINTENANCE
Proposed Changes & Observations
________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
3.0 BTM SPINNING - PRODUCTION
________________________________________________________________________________________
National Productivity Council, Bangalore.
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___________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
3.0
3.1
I II III G T I II III G T
1 MIXING Mixing Man 7 7 7 - 21 6 6 6 - 18
Beater Opener 1 1 1 - 3 1 1 1 - 3
Waste Sorter - - - 1 1 - - - 1 1
2 BLOW-ROOM Tenter 4 4 4 - 12 4 4 4 - 12
3 CARDING Tenter 3 3 3 - 9 3 3 3 - 9
Lap Carrier 2 2 2 - 6 2 2 2 - 6
4 DRAWFRAME Jobber 1 1 1 - 3 1 1 1 - 3
D/F Tenter 3 3 3 - 9 3 3 3 - 9
5 SIMPLEX S/F Tenter 5 5 5 - 15 5 5 5 - 15
Doffer 3 3 3 - 9 3 3 3 - 9
Floor Cleaner 1 1 1 - 3 1 1 1 - 3
Helper / Reliever 1 1 1 - 3 1 1 1 - 3
6 RING-FRAME Doffing Reliever 3 3 3 - 9 3 3 3 - 9
Checker 1 1 1 - 3 2 2 2 - 6
Sider 13 13 13 - 39 13 13 13 - 39
Doffer 18 18 18 - 54 18 18 18 - 54
Doffer-Leader 3 3 3 - 9 3 3 3 - 9
Floor Cleaner 3 3 3 - 9 3 3 3 - 9
BTM SPINNING - PRODUCTION
Manpower Deployment *
S. No Section / Work area Designation
Present Manpower Proposed Manpower
Remarks
_________________________________________________________________________________________________________________________________
National Productivity Council, Bangalore.
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___________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
3.0
3.1
I II III G T I II III G T
BTM SPINNING - PRODUCTION
Manpower Deployment *
S. No Section / Work area Designation
Present Manpower Proposed Manpower
Remarks
Runnning Fitter 1 1 1 - 3 1 1 1 - 3
7 AUTO-CONER Reliever 2 2 2 - 6 1 1 1 - 3
Material Man 2 2 2 - 6 2 2 2 - 6
Kirchi Man 2 2 2 - 6 2 2 2 - 6
Floor Cleaner 2 2 2 - 6 2 2 2 - 6
Helper in Savio
No. 7
1 1 1 - 3 1 1 1 - 3
Rejection Rewinder - - - 1 1 - - - 1 1
Winder 16 16 16 - 48 8 8 8 - 24
Jam Cutting - - - 1 1 - - - 1 1
8 CHEESE WINDER Winder 10 10 10 - 30 7 7 7 - 21
Leewha Winder 1 1 1 - 3 1 1 1 - 3
9 TFO Jobber 1 1 1 - 3 1 1 1 - 3
Reliever/Helper 2 2 2 - 6 2 2 2 - 6
Sr. Checker /
Jobber
- - - 1 1 - - - 1 1
Tenter 12 12 12 - 36 12 12 12 - 36
10 PACKING Checker - - - 3 3 - - - 3 3
_________________________________________________________________________________________________________________________________
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___________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
3.0
3.1
I II III G T I II III G T
BTM SPINNING - PRODUCTION
Manpower Deployment *
S. No Section / Work area Designation
Present Manpower Proposed Manpower
Remarks
Lot Final Checker - - - 2 2 - - - 1 1
Packer - - - 6 6 - - - 5 5
11 S.Q.C. Checker &Investigator3 2 - 1 6 3 2 - 1 6
127 126 124 16 393 115 114 112 14 355
* The above manpower deployment table is for 30s Count.
Total
_________________________________________________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
3.0
3.2
3.2.1
I
a)
b)
c)
d)
M
/
C

N
a
m
e
P
r
o
d
u
c
t
i
o
n

(
k
g
s
)

/
H
o
u
r
P
a
r
a
m
e
t
e
r
s
O
u
t
p
u
t

Q
u
a
n
t
i
t
i
e
s
CARDING-
LR C1/3
15.9
12 Kg/
Can
D/F
Breaker
78.26
10
Kg/Ca
n
D/F
Finisher
209.17
14
kg/Can
Speed
frame
66.55
108
spindle/
machine
1.3 Kg/
Roving
It is assumed that machines are subject to stops at random and unpredictable intervals. It is
also assumed that the operator will service a machine with the minimum delay after the
machine has stopped, and that if two or more are stopped at one time,he will attend to them
by taking the nearest first. This method of servicing is called random tending. Thomas
F.O' Connor, provided the table for calculating the machine efficiency and operators
workload in this type of multimachine assignment problem in the book: Efficiency and
Productivity Tables for Textile Machine Operation, Institute of Textile
Technology,Virginia.
Proposed Changes & Observations
62.61
119.53
409.54
BTM SPINNING - PRODUCTION
o
u
t
p
u
t

p
e
r

s
h
i
f
t

p
e
r

m
a
c
h
i
n
e
10.60
Methodology
The machine efficiency and operator workload are depicted in the graph to findout the
optimum (where running efficiency & operative workload meets) number of machines to be
alloted per personnel.
Carding,Drawframe and Speedframe
In Carding, Drawframe and Speed frame sections, the operator is responsible for the
operation of more than one machine, if two machines stop at a time and require tenter's
attention simultaneously,one of the machine must wait until he completes his work on the
other. This time loss representing waiting time due to overlapping of machine stoppage is
called "Interference loss".
The frequency values are taken from the following tables for the repsective sections:
I
n
p
u
t

p
e
r

s
h
i
f
t

p
e
r

m
a
c
h
i
n
e
7.71
52.17
167.34
38.03
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
3.0
3.2 Proposed Changes & Observations
BTM SPINNING - PRODUCTION
3.2.1
II
a)
b)
c)
d)
e)
Methodology
The working pattern of operators in Ringframe, Autconer, Cheese winding and Two-for-
One(TFO) is entirely different from the preceding section.In this areas,the operator's
services the machine in a cyclical manner and attends to each machines(drums) as he
comes to it.
The research paper "The Efficiency of N machines Uni-Directionally patrolled by
single operative" by Mr.C.Mack,T.Murphy and N.L.Webb,Journal of the Royal
Statistical Society, (1957), is used to arrive the machines running efficiency for the
different number of machines handled by the operators in the above sections considering
the following working methodology:
- Random breakdowns in running time @ each machine/drum
N - Number of machines
The operative walks round the machines in a defined order and repairs and restarts any
machine which is found stopped, passing after inspecting and/or servicing any machine
which is running. It is assumed that the machine stops at random with the same mean
frequency and independent of each other.
The difficulty in dealing with these problems lies in calculating the effect of "interference"
which is the term used for incidence of simultaneous stoppages at several machines. In fact,
if the optimum number of machines is being controlled by one operative, the machine
efficiency required will be a marked feature.
The running efficiency is arrived by the following formula provided by the research paper.
= Running Efficiency, i.e the percentage of running time to total (stopped +
running) time.Stopped means time lost due to interference and breaks and
rectification of breaks.
K- Mean walking time from one machine to next machine, includes inspection time
= (b-1) / [ N{K+(b-1)C}]
C - Time to repair and restart the machine
Ringframe, Autoconer, Cheesewinding and Two-for-One(TFO)
b = exp( NK)
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
3.0
3.2 Proposed Changes & Observations
BTM SPINNING - PRODUCTION
3.2.1
f)
g)
h)
M
/
C

N
a
m
e
P
r
o
d
u
c
t
i
o
n

(
K
g
s
)
/

H
o
u
r
s
M
a
c
h
i
n
e

P
a
r
a
m
e
t
e
r
s
O
u
t
p
u
t
A
v
a
i
l
a
b
l
e

h
o
u
r
s
/

S
h
i
f
t
M
/
C

a
v
a
i
l
a
b
l
i
t
y

l
o
s
t

%

*
M
/
C

A
v
a
i
l
a
b
i
l
i
t
y

(
%
)
T
o
t
a
l

T
i
m
e

a
v
a
i
l
a
b
l
e

f
o
r

p
r
o
d
u
c
t
i
o
n
I
n
p
u
t

p
e
r

s
h
i
f
t

o
f

r
e
s
p

e
f
f
i
c
i
e
n
c
y

p
e
r

m
/
c
o
u
t
p
u
t

p
e
r

s
h
i
f
t

o
f

r
e
s
p

e
f
f
i
c
i
e
n
c
y

p
e
r

m
/
c
R/F-
Texmaco
8.75
440
spindle/
machine
58 gms
Bobbin
8 9.50% 91.5% 7.32 49.27 1105.00
R/F-LR 10.17
432
spindle/
machine
58 gms
Bobbin
8 9.50% 91.5% 7.32 57.26 1284.00
Autocone
r-Espero
59.68
60
spindle/
machine
2 Kg Cone 8 30% 70.0% 5.6 5761.72 167.09
Cheese
Winding-
RJK
150
120
spindle/
machine
1 Kg
Cheese
8 29% 71% 5.68 186.16 372.32
TFO-VJ 9.32
144
spindle/
machine
2 Kg Cone 8 4% 96.0% 7.68 71.56 35.78
TFO-
PRERNA
9.32
144
spindle/
machine
2 Kg Cone 8 4% 96.0% 7.68 71.56 35.78
Methodology
The frequency values are taken from the following tables for the repsective sections:
The operator workload is calculated by multiplying the time taken for different activities to
be performed with the frequency of the activities for the allotted number of machines.
The running efficiency values and operator workload are depicted in the graph to findout
the optimum (where running efficiency & operative workload meets) number of drums to
be alloted per personnel.
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
3.0
3.2 Proposed Changes & Observations
BTM SPINNING - PRODUCTION
3.2.2
I
a)
II
a)
III
a)
b)
IV
a)
V
a)
b)
VI
a)
VII
a)
It is recommended to allocate 60 drums per operator(6 machines) and 64 drums per
operator in the remaining to machines. The machine efficiency would be decrease where 64
drums allocated per operator.
Cheesewinding -Winder
Autoconer -Winder
Proposed Changes
Mixing Blenders:
Deploy five personnel as the packer instead of present six personnel. The proposed
utilisation would be 86.74%
Packing - Packers
In view of low utilisation (46.43% ), it is recommended to deploy one personnel as reliever
instead of the present two personnel who is presently releiveing autoconer winder in
machine 2,1,5 & 6. The operator workload would be reduced as the number of winders to
be relieved is become half.
It is suggested to deploy two cheker per shift as checker (three units) in ringframe section
instead of present one person per shift.
Based on utilisation (74.47 %), it is recommended to deploy six personnel instead of the
present seven personnel in a shift for three mixing blenders operation. The proposed
utilisation of six personnel would be 86.88%
From the analysis,it is found that the optimum number of drums to be assigned is 60 drums
per operator. At present, one operator is alloted 30 drums(in two machines 32
drums/operator).
Autoconer -Reliever
Deploy one personnel for lot final checking activity instead of two personnel persently. The
proposed utilisation would be 94.33%
In BTM Spinning, the four cheese winding machines are in one section and two machines
are in unit-3. Based on the above findings, two personnel is recommended for unit-3
machines(2 nos) and five personnel for four machines in the unit-1 &2.
From the analysis,it is found that the optimum number of drums to be allocated is 120
drums per operator. At present, one operator is assigned 64,76,80 drums depends on the
machine capacity.
Packing - Lot final Checker
Ringframe -Checker
________________________________________________________________________________________
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3.0
3.3
S.No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
BSP/W/09
BSP/W/07
Ringframe-Doffer BSP/W/14
Speedframe -Reliever BSP/W/11
Speedframe-Floor Cleaner BSP/W/12
Ringframe-Sider BSP/W/13 & A
Speedframe Tenter
BSP/W/23
BTM SPINNING - PRODUCTION
Workload Sheets Summary
Area of work WLS Number
Mixing Man BSP/W/01
Speedframe Doffer BSP/W/10
Drawframe-Jobber
Ringframe-Doffer Reliever BSP/W/16
Autoconer-Winder
BSP/W/22
Ringframe-Running Fitter BSP/W/17
Ringframe-Checker BSP/W/18
Ringframe-Floor cleaner BSP/W/19
Beater Opener BSP/W/02
Blowroom Tenter BSP/W/04
Waste Sorter BSP/W/03
Carding Tenter BSP/W/05
Lap Carrier
TFO- Jobber BSP/W/30
Ringframe-Doffer leader BSP/W/15
Cheesewinding-Winder(SSM) BSP/W/28
Cheesewinding-Leewha BSP/W/29
Autoconer-Reliever BSP/W/20
TFO- Tenter BSP/W/33 & A & B
TFO- Sr.Jobber BSP/W/32
BSP/W/06
Drawframe Tenter BSP/W/08
BSP/W/27
BSP/W/26 Autoconer-Helper in Savio No.7
BSP/W/37 QA- Checker & Investigator
Packing - Checker BSP/W/34
Packing -Lot Final Checker BSP/W/35
Packing -Packer BSP/W/36
Autoconer-Material Man BSP/W/21
Autoconer-Kirchiman
Autoconer-Jam Cutting
TFO- Reliever BSP/W/31
Autoconer-Floor Cleaner BSP/W/25
Autoconer-Rejection rewinder BSP/W/24
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 7 7 7 -
Designation Proposed Manpower 6 6 6 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total Time
(Mins)
1
a
1 1 4.95 4.95
b
1 1 2.48 2.48
c 2 1 10.50 21.01
d
1 1 4.00 4.00
d 1 1 1.13 1.13
2
a
2 5 3.92 39.15
b 1 5 1.42 7.11
c
1 2275 0.026 59.32
d
1 2275 0.028 62.73
e
1 20 3.85 77.00
f
1 1225 0.12 144.12
g
1 41 2.07 84.87
h
1 3500 0.08 280.00
3
a
b
4
a
b
5
Bring the hot water in a plastic drum from geyser
Mix the AS-200 & AS-400 one by one in the hot
water
WLS No: BSP/W/01
WORK LOAD DETAILS SHEET
BTM Spinning
Shifts A B C G
Blender
Mixing Boy
Activity Description
Spin Finish Solution preparation ( No 1 & 3)(in
front of shift incharge)
Bring the chemical ( AS 400) from the plastic drum
in the presence of supervisor after weighing
Mixing Room
Bring the chemical ( AS 200) from the plastic drum
in the presence of supervisor after weighing
1 3500
Keep the empty chemical cans in the respective area
Layering
Bring the polyester bags from respective area to
near the machine
Open the bales of polyester bags
Take the polyester from bags and put it on the belt
conveyor(feed end)
Spread the blender output (inside the bin) evenly by
manual
Spray the spin finish solution uniformly on the layer
of polyester fibre using spray pump
Fill the viscose in the bag from the viscose room
0.11 385.00
Spread the blender output (inside the bin) evenly by
manual
Final Toppling (Mixing)
Move the bags from room to mixing room
Do layering by spreading polyester and viscose on
the alternate layer by manually
First Toppling (Mixing)
Cut the material vertically in the mixing bin, lift and
feed on blender belt conveyor
Second Toppling (Mixing)
Cut the material vertically in the mixing bin, lift and
feed on blender belt conveyor
1 3500 0.11 385.00
Spread the blender output (inside the bin) evenly by
manual
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 7 7 7 -
Designation Proposed Manpower 6 6 6 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total Time
(Mins)
WLS No: BSP/W/01
WORK LOAD DETAILS SHEET
BTM Spinning
Shifts A B C G
Blender
Mixing Boy
Activity Description
Mixing Room
a
b
6
a
b
c
d
A 2005.03
B 17
C 2345.88
D 450
E 74.47%
F 6
G 86.88%
Target - 2500 Kg /person * 7 persons / shift =17500 kg / shift . Each batch have 5 steps. It
becomes 3500 kg batch ( 3500 * 5 steps = 17500 kg)
Cut the material vertically in the mixing bin, lift and
feed on blender belt conveyor
1 3500 0.11
62.17
Clean the blender & beater
Clean the floor area around the machine
To remove the jam of beater & blender ( if any)
1 62.17
385.00
Spread the blender output (inside the bin) evenly by
manual
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Net Available man-mins
Lot Change ( Shade Change)
Clean the bins before starting the mixing.
1
As minimum two personnel required per mixing room, six personnel is being recommended per
shift for three blowrooms.
Proposed Utilisation(%)
Remarks:
Present Utilisation(%)
Proposed Manpower per shift
P/V (65/35) mixing is considered. Hence , 3500 *65% Polyester = 2275 kg / shift , 3500 * 35%
Viscose =1225 kg/ shift.
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 1 1 1 -
Designation Proposed Manpower 1 1 1 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
1 1 19.00 19.00
2
a
1 41 0.09 3.69
b 1 41 0.29 11.89
c 1 41 0.35 14.27
d 1 41 1.00 41.08
e
1 41 0.38 15.38
f 1 41 0.05 2.05
3
1 3 15.00 45.00
A 152.36
B 14
C 173.68
D 450
E 38.60%
F 1
G 38.60%
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Remarks:
Viscose required per shift ( Mixing WLS sheet) = 1015 kg
Number of Viscose bags to be opened = 1015/ 25 bag = 41 bag/shift
Collect the empty bag, tags and keep aside
Clean the beater & bin (colour change)
Basic Workload per Shift ( in man minutes)
Take the bags and move back to the belt conveyor
Open the bag (25 Kg / Bag)
Dump the viscose on the belt conveyor from bag
In the middle go to room and spread the opened the
viscose manually(time per bag)
Net Available man-mins
Total Workload ( in man minutes )
Mixing Room
Viscose bag (Fibre dyeing section)
Move from belt conveyor of beater to bags storage
area(mean distance is considered)
Rest & Relaxation Allowances ( % )
Beater
Beater Opener
Activity Description
Clean the bow room walking path from (1-5) and area
under cleaning using the broom stick(lengthy)
WLS No: BSP/W/02
WORK LOAD DETAILS SHEET
BTM Spinning
Shifts A B C G
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 1
Designation Proposed Manpower - - - 1
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 357 KG 164.22 164.22
2
1 24 bags 16.80 16.80
3
1 24 bags 120.00 120.00
4 1 4 32.00 32.00
A 333.02
B 13
C 376.31
D 480
E 78.40%
F 1
G 78.40%
Proposed Manpower per shift
Proposed Utilisation(%)
Remarks:
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Weight the waste and maintain the record in the
register
Put the waste in the bags and placed in the waste
room category wise.
Department general work.
Basic Workload per Shift ( in man minutes)
Net Available man-mins
Present Utilisation(%)
Sort out the waste shade wise and category wise
WLS No:BSP/W/03
WORK LOAD DETAILS SHEET
BTM
Shifts A B C G
PREPARATORY
MIXING
WASTE SORTER
Activity Description
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 4 4 4 -
Designation Proposed Manpower 4 4 4 -
Sl.
No
Crew
Size
Freq/
machi
ne /
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
a
1 1 2.00 2.00
b 1 1 5.00 5.00
2
1 828 0.076 62.93
3 1 57 0.290 16.53
4 1 57 0.096 5.47
5
1 57 0.175 9.98
6 1 57 0.510 29.07
7 1 54 0.150 8.10
8 1 3 2.310 6.93
9
1 2 5.00 10.00
10
1 0.97 120.00 116.40
A 272.41
B 15
C 313.27
D 450
E 69.61%
F 1
G 69.61%
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Rejection (5%) = 54.33 *5% = 2.71 laps
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Break rejected laps into small tufts and feed them equally
Clean the machine area at the shift end and at intervals.
Clean the machine during lot change
Remarks:
Machine capacity - 107.63 kg / 14.5 kg lap = 7.42 * 7.33 hours = 54.33 laps
Bring the materials from mixing bin room (vertical cut)&
feed on the machine lattice
Keep the spindle on machine stand for next lap
Keep the lap rod in the machine for new lap
Remove the laprod from the machine and keep on the
weighing machine and ensure that lap weight is under
tolerance limit. +/-200 gms
Take the polycover and tie on the lap
Mixing
Blowroom
Tenter
Activity Description
Shift Changeover activities
Check the machine parameters like length
counter,count,batch,shade no etc
Counter check weight of 5 laps of out going shift.
Lot Change = 350 / month = 350 / (90 shifts*4 machine) =0.97 / shift/machine
WLS No: BSP/W/04
WORK LOAD DETAILS SHEET
BTM Spinning
Shifts A B C G
Keep the lap in the respective zone
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 3 -
Designation Proposed Manpower 3 -
Sl.
No
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1 t2 1 9 1.00 13 10.17
13 t2 7.68 9 0.24 16 19.35
14 t2 7.68 9 0.31 13 23.98
15 t2 7.68 9 0.44 15 35.22
16 t2 7.68 9 0.21 14 16.56
21 t2 10.64 9 0.63 13 68.17
22 t2 10.64 9 0.35 13 37.44
23 t 0.4256 9 1.15 13 4.98
24 t1 2 9 1.06 13 21.56
25 t2 2 9 1.50 13 30.51
26 t1 2 9 1.61 13 32.80
27 t1 2 9 2.49 13 50.65
28 t1 2 9 1.21 13 24.55
29 t1 1 2 4.36 13 9.85
31 t2 1 9 1.02 13 10.37
33 t1 1 1 0.60 13 0.68
34 t1 1 1 1.02 13 1.15
35 t1 1 1 4.10 13 4.64
36 t 0.149 9 15.00 13 22.73
WLS No: BSP/W/05
WORK LOAD DETAILS SHEET
BTM
Shifts A B C G
Spinning
Carding 3 3
Tenter 3 3
LR
Load new lap rod on the machine stand
from trolley/floor
Activity Description
Reset the machine parameter at the shift
starting
Front side wheel-LR
Remove the lap cover from the lap
Feed the lap on the machine (from machine
stand to roller)
Remove the empty lap rod from the machine
& place on the trolley
Bring the empty can and keep on the
machine
Move the filled can from the machine and
keep in the respective area
Attend the sliver cut problem
Front side top-LR
Thomas O Connor table
Front side bottom-LR
Back side bottom-LR
side door-LR
Clean the work area around the machines
Clean the bruce wheel at the shift end and
collect the waste
Bring the yellow bag from blow room
Move the waste collected to blow room
section yellow bag
Hand over the waste collected in the carding
section after weighment at the shift end
Clean the machine at the time of lot change
T (M/C running time per cycle) = 480 mins per shift *9 machines =4320 mins
t1(Average time in min taken by operator per mrh to perform necessary deferrable work while
m/c is running) = 145.88 mins
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 3 -
Designation Proposed Manpower 3 -
Sl.
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WLS No: BSP/W/05
WORK LOAD DETAILS SHEET
BTM
Shifts A B C G
Spinning
Carding 3 3
Tenter 3 3
Activity Description
t2 (Average time in min taken by operator per mrh to perform non-deferrable work while m/c
is running ) = 251.77 mins
t (Average time in min taken by operator per mrh to perform non-deferrable work with the
machine stopped) = 27.71 mins
The machine efficiency and respective operative workload for the values above is found out
from the Thomas O' Connar table and tabulated below:
No of Machines Machine Efficiency(%) Operator workload(%)
9 94.31% 83.57%
Lot Change = 350 / month = 350 / (90 shifts*26 machine) =0.149 / shift/machine
The above values are depicted in the graph to find out the optimum (where running efficiency
& operative workload meets) number of drums to be allotted per personnel and presented
below:
From the graph, the optimum number of machine can be allotted per operator is 10 nos.
Remarks:
10 93.27% 91.83%
11 92.10% 99.76%
9 10 11
Machine Efficiency(%) 94.31% 93.27% 92.10%
Operator Workload(%) 83.57% 91.83% 99.76%
75.00%
80.00%
85.00%
90.00%
95.00%
100.00%
105.00%
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Carding-LR+Crossrol
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 2 2 2 -
Designation Proposed Manpower 2 2 2 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
1
17 per
lap man
59.84 59.84
2
1
124 per
lap man
97.96 97.96
3
1
17 per
lap man
50.32 50.32
4
1 1 40.00 40.00
5 1 2 97.20 97.20
A 345.32
B 14
C 393.66
D 450
87.48%
F 1
G 87.48%
Proposed Manpower per shift
Proposed Utilisation(%)
Remarks:
Two personnel is recommended per shift for the carding section. The above workload sheet is for
single personnel
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Creel the lap to the carding machine
Collect and send back the lap rod to the blowroom
section.
Relieve the card tenter for the lunch and tea break
General cleaning of the machine and lot change
Basic Workload per Shift ( in man minutes)
Net Available man-mins
Present Utilisation(%)
Carry the lap from blowroom section to the carding
machine.
WLS No: BSP/W/06
WORK LOAD DETAILS SHEET
BTM
Shifts A B C G
PREPARATORY
CARDING
LAP MAN
Activity Description
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 1 1 1 -
Designation Proposed Manpower 1 1 1 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
1 1 15.83 15.83
2 1 1 30.00 30.00
3 1 1 30.00 30.00
4
1 1 10.83 10.83
5
1
14.75 %
of 5.60
hrs
49.56 49.56
6 1 4 14.68 14.68
7
1
2 S/F
m/c & 4
D/F m/c
8 1 1
9 1 4 41.40 41.40
A 276.31
B 13
C 312.23
D 450
E 69.38%
F 1
G 69.38%
CP change in case of lot change
Basic Workload per Shift ( in man minutes)
Help doffer & helper in lot change cleaning
Wrapping of new lot & checking for defect
Roller treatment
84.00 84.00
Cot belt treatment
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Remarks:
Proposed Manpower per shift
Proposed Utilisation(%)
Net Available man-mins
Present Utilisation(%)
Ensure the m/c are attended in case of
stoppages/breakdowns
WLS No: BSP/W/07
WORK LOAD DETAILS SHEET
BTM
Shifts A B C
Drawframe &Simplex
JOBBER
G
Drawframe &Simplex
Adjust hands shortage
Relieve 1 tenter for lunch
Activity Description
Collect cards from workers and take charge of the
dept.
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre
Present
Manpower
3
Designation
Proposed
Manpower
3
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A
1 t2 52.17 0.46 2 13 54.24
2 t2 52.17 0.40 2 13 47.16
3 t2 52.17 0.20 2 13 23.58
4 t2 62.61 0.24 2 13 33.96
5 t 4 0.98 2 13 8.86
6 t 4 0.50 2 13 4.52
7 t 3.7566 0.40 2 13 3.40
8 t 0.648 0.17 2 13 0.24
B
1 t2 167.34 0.25 1 13 47.27
2 t2 167.34 0.29 1 13 54.84
3 t2 119.53 0.26 1 13 35.12
4 t2 119.53 0.27 1 13 36.47
5 t 4 0.98 1 13 4.43
6 t 4 0.50 1 13 2.26
7 t 4.7812 0.55 1 13 2.97
8 t 4.7812 0.75 1 13 4.05
9 t 1.29 0.17 1 13 0.24
Breaker
Spinning
Drawframe
Tenter
Activity Description
3 3
3
Bring the full materials cans(Carding
sliver) from carding section
Replace the empty carding sliver cans
with the full carding sliver can &piece
the sliver in LDO/6
Return the empty cans to the carding
section & keep in the area earmarked
Place the empty cans in LDO/6 for
doffing
Change top rolls once in every two
hours
Clean the drafting zone and filter box
once in every two hours
Do the lot change cleaning
Piece the ends during breakages
Do the lot change cleaning
Finisher
Move the LDO/6 material cans to the
Cherry Hara D/F(input)
Replace the empty cans by the
materials cans & join the sliver
Place back the empty cans in Cherry
Hara for doffing
Remove the materials cans from cherry
hara & Keep in Simplex area
Change top rolls once in every two
hours
Clean drafting zone and filter box once
in every two hrs.
Piece the ends during breakages
Remove the roller jam
3
BTM Spinning
Shifts
WLS No: BSP/W/08
WORK LOAD DETAILS SHEET
A B C G
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre
Present
Manpower
3
Designation
Proposed
Manpower
3
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Spinning
Drawframe
Tenter
Activity Description
3 3
3 3
BTM Spinning
Shifts
WLS No: BSP/W/08
WORK LOAD DETAILS SHEET
A B C G
C t1 1 3.00 1 13 3.39
65.29%
The machine efficiency and respective operative workload for the values above is found out
from the Thomas O' Connar table and tabulated below:
t (Average time in min taken by operator per mrh to perform non-deferrable work with the
machine stopped) = 30.98 mins
No of Machines
Machine
Efficiency(%)
Operator workload(%)
Collect waste and hand over to mixing
for weighment
t2 (Average time in min taken by operator per mrh to perform non-deferrable work while m/c
is running ) = 332.64 mins
Thomas O Connor table
t1(Average time in min taken by operator per mrh to perform necessary deferrable work while
m/c is running) = 3.39 mins
T (M/C running time per cycle) = 480 mins per shift *3 machines = 1440 mins
79.41%
89.12%
95.02%
5
4
The above values are depicted in the graph to find out the optimum (where running efficiency
& operative workload meets) number of drums to be allotted per personnel and presented
below:
69.93%
62.14%
85.39%
77.89%
3
6
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre
Present
Manpower
3
Designation
Proposed
Manpower
3
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Spinning
Drawframe
Tenter
Activity Description
3 3
3 3
BTM Spinning
Shifts
WLS No: BSP/W/08
WORK LOAD DETAILS SHEET
A B C G
From the graph, Optimum number of machine to be alloted per operator is 4. But, the breaker
and finisher is a group of machine and also the layout of BTM(unit1,2 &3 away from each
other), it is not recommended to spilt and allocate to separate personnel.
The above workload sheet is for machine in Unit-1. It has been selected for calculation
,because the capacity of machine is high in unit-1 compared to unit-2 &3.
It is recommended that one operator per two breaker and one finisher machine.
Lot Change = 350 / month = 350 / (90 shifts*3 machine) =0.97 / shift/machine
Remarks:
3 4 5 6
Machine Efficiency(%) 85.39% 77.89% 69.93% 62.14%
Operator Workload(%) 65.29% 79.41% 89.12% 95.02%
0.00%
10.00%
20.00%
30.00%
40.00%
50.00%
60.00%
70.00%
80.00%
90.00%
100.00%
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Drawframe-Tenter
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre
Present
Manpower
5
Designation
Proposed
Manpower
5
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s
)
A
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e
(
%
)
T
o
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a
l

T
i
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(
M
i
n
s
)
1 t2 38.03 2 0.60 13 51.57
2 t2 38.03 2 0.22 13 18.91
3 t1 4 2 2.65 13 23.96
4 t1 4 2 1.65 13 14.92
5 t1 4 2 1.00 13 9.04
6 t 4 2 5.00 13 45.20
7 t 4.095 2 0.62 13 5.74
8 t 4.095 2 1.11 13 10.27
9 t 4.095 2 0.75 13 6.94
10
a t2 0.43 2 21.60 13 20.99
b t2 0.43 2 37.80 13 36.73
c t 0.43 2 90.00 13 87.46
11 t 0.098 2 60.00 13 13.29
1
2
3
4
The machine efficiency and respective operative workload for the values above is found out
from the Thomas O' Connar table and tabulated below:
Idle spindle
Remove the Top/Bottom Roller jam
Piece the broken roving
Move empty can near the D/F
Move the full D/F cans from D/F can
storage area to S/F machine & put the sliver
on the top roller
Lot change
Perform Count changing activity(replace
empty can with the full can, piece the sliver
with the roving &start the machine)
Move the full D/F cans (from D/F can
storage area) to S/F machine & replace the
empty cans.
Clean the draft zone(green box front side)
Clean the top roller clearer cloth(back side)
Keep the empty cans colour wise near the
D/F can storage area
Activity Description
Clean the fan waste
Calculation of workload using Thomas O Connor table:
T (M/C running time per cycle) = 480 mins per shift *2 machines = 960 mins
t1(Average time in min taken by operator per mrh to perform necessary deferrable work
while m/c is running) = 47.91 mins
Machine stoppage for doffing
t2 (Average time in min taken by operator per mrh to perform non-deferrable work while m/c
is running ) = 128.20 mins
t (Average time in min taken by operator per mrh to perform non-deferrable work with the
machine stopped) = 168.90 mins
Piece the ends of Finisher Sliver
Piece the sliver with the roving
5
Tenter 5 5
Speed Frame 5
WLS No: BSP/W/09
WORK LOAD DETAILS SHEET
BTM Spinning
Shifts A B C G
Spinning
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre
Present
Manpower
5
Designation
Proposed
Manpower
5
5
Tenter 5 5
Speed Frame 5
WLS No: BSP/W/09
WORK LOAD DETAILS SHEET
BTM Spinning
Shifts A B C G
Spinning
Count Change = 80 / month = 80 / (90 shifts*9 machine) = 0.098 / shift/ unit
4 65.61% 94.32%
Lot Change = 350 / month = 350 / (90 shifts*9 machine) =0.43 / shift/machine
The above values are depicted in the graph to find out the optimum (where running
efficiency & operative workload meets) number of drums to be allotted per personnel and
presented below:
2 79.29% 56.99%
No of Machines
Machine
Efficiency(%)
Remarks:
From the graph, Optimum number of machine to be alloted per operator is two.
3 72.79% 78.48%
Operator
workload(%)
Whereas in Count change, all the activity is performed, when machine is in stopped condition.
Doffers helps during count change.
Lot change is being performed for half of the machine and during that time the remaining half
machine is in running condition. Machine gets stopped only when piecing of sliver with roving
done. It is considered that all the activities for lot change has been performed only by the tenter.
2 3 4
Machine Efficiency(%) 79.29% 72.79% 65.61%
Operator Workload(%) 56.99% 78.48% 94.32%
0.00%
20.00%
40.00%
60.00%
80.00%
100.00%
E
f
f
i
c
i
e
n
c
y
(
%
)
Speedframe -Tenter
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 3 3 3 -
Designation Proposed Manpower 3 3 3 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
3 3600 216.00 648.00
2
3 3600 126.47 379.42
3
3 1 10.00 30.00
4
3 1 30.00 90.00
A 1147.42
B 13
C 1296.59
D 1350
E 96.04%
F 1
G 96.04%
To clean the simplex machine (Bobbin rail and
spindle section)
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Doffing of the rove bobbin at the doff of the
machine
Remarks:
SIMPLEX
Keep the doffed bobbin in the racks
Sorting the simplex waste and send it to the
blowroom section.
G
SIMPLEX
DOFFER
Activity Description
WLS No: BSP/W/10
WORK LOAD DETAILS SHEET
BTM
Shifts A B C
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 1 1 1 -
Designation Proposed Manpower 1 1 1 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
1 6 tenter 378.00 378.00
A 378.00
B 13
C 427.14
D 450
E 94.92%
F 1
G 94.92%
6 tenter - (5 S/F & 1 D/F)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Relieve the machine tenter for lunch and tea break and
do the tenter activities during that time.
Remarks:
SIMPLEX
Basic Workload per Shift ( in man minutes)
G
SIMPLEX
RELIEVER
Activity Description
WLS No: BSP/W/11
WORK LOAD DETAILS SHEET
BTM
Shifts A B C
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 1 1 -
Designation Proposed Manpower 1 1 -
Sl.
No
Crew
Size
Total
Sq.
meter
Freq/
shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 8234 4 350.00 350.00
A 350.00
B 13
C 395.50
D 450
E 87.89%
F 1
G 87.89%
WLS No: BSP/W/12
WORK LOAD DETAILS SHEET
BTM
Shifts B C G
SIMPLEX
SIMPLEX
Floor cleaner
Activity Description
Clean the preparatory work area
Basic Workload per Shift ( in man minutes)
A
1
1
Remarks:
24702 sq.feet = 8234 sq.met per shift
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre
Present
Manpower
13 -
Designation
Proposed
Manpower
13 -
Sl.
No
Crew
Size
Freq/
Shift
No of
Machi
ne
Basic
Time
(Mins)
Allo
wanc
e
(%)
Total
Time
(Mins)
1 1 432 1.5 0.13 13 95.19
2 1 1 1 20.52 13 23.19
3
1 51.34 4 0.54 13 125.31
1 51.34 4 0.22 13 51.05
1 51.34 4 0.40 13 92.82
4
1 0.081 4 4.00 13 1.46
1 0.081 4 4.00 13 1.46
5
1 0.018 4 4.00 13 0.33
1 0.018 4 4.00 13 0.33
6
1 18 4 0.02 13 1.87
1 18 4 0.41 13 33.36
1 18 4 0.02 13 1.87
7 1 4 4 0.33 13 5.97
A 434.21
B 480
C 90.46%
5
13
Sider
13 13
WLS No: BSP/W/13
WORK LOAD DETAILS SHEET
BTM Spinning
Shifts A B C G
Spinning
Remove the top clearer, clean and keep on
the lammba
Put the top clearer on the machine after the
count change over
Activity Description
Top clearer cleaning
Ringframe-
LR(432 Spindle)
13
Drafting zone cleaning
To attend idle spindles in his m/c
Remove roller lapping using hexablade
knife
Piece the broken threads
Roving cut join
Lot change
Present Utilisation(%)
The running efficiency is arrived by the formula provided in the research paper : The
Efficiency of N machines Uni-Directionally patrolled by single operative by
Mr.C.Mack,T.Murphy and N.L.Webb,Journal of the Royal Statistical Society, (1957).
Count change
Remove the top clearer, clean and keep on
the lammba
Put the top clearer on the machine after the
count change over
S/F Roving Change
Bring the S/F roving near the machine from
the S/F roving storage area
Replace the empty rovings with the new
rovings
Place the empty rovings in the area
To collect pnumafil waste and hand over it
to mixing for weighment at the shift end.
Basic Workload per Shift ( in man minutes)
Net Available man-mins
= (b-1) / [ N{K+(b-1)C}]
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre
Present
Manpower
13 -
Designation
Proposed
Manpower
13 -
Sl.
No
Crew
Size
Freq/
Shift
No of
Machi
ne
Basic
Time
(Mins)
Allo
wanc
e
(%)
Total
Time
(Mins)
13
Sider
13 13
WLS No: BSP/W/13
WORK LOAD DETAILS SHEET
BTM Spinning
Shifts A B C G
Spinning
Activity Description
Ringframe-
LR(432 Spindle)
13
1944 (432*4.5) 83.40%
The running efficiency is calculated using the above formula for different number of drums
and tabulated below:
No of Spindles
Running Efficiency
() (%)
Operator workload(%)
- 0.000499, N - 1728 (432*4), C - 0.22, K - 0.03
1728 (432*4) 84.97% 90.46%
106.91%
Remarks:
Lot Change = 350 / month = 350 / (90 shifts*48 machines) =0.0812 / shift
The above values are depicted in the graph to findout the optimum (where running efficiency
& operative workload meets) number of drums to be alloted per personnel and presented
below:
From the graph, the optimum number of spindle can be alloted per operator is 1728 nos
Count Change = 80 / month = 80 / (90 shifts*48 machines) = 0.018 / shift
Speedframe rovings is changed mainly during the lot change and Count change. As the activities
are performed during lot&count change it is being considered under the doffers workload. But
small percentage(30%) of S/F rovings is being changed by sider ( while running).Number of
rovings to be feed per ringframe per shift equals to 58 rovings.
98.69%
2160 (432*5) 81.89%
1728
(432*4)
1944
(432*4.5)
2160
(432*5)
Running Efficiency ()
(%)
84.97% 83.40% 81.89%
Operator workload(%) 90.46% 98.69% 106.91%
0.00%
20.00%
40.00%
60.00%
80.00%
100.00%
120.00%
E
f
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i
c
i
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n
c
y
(
%
)
Ringframe-LR
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre
Present
Manpower
13 -
Designation
Proposed
Manpower
13 -
Sl.
No
Crew
Size
Freq/
Shift
No of
Machi
ne
Basic
Time
(Mins)
Allo
wanc
e
(%)
Total
Time
(Mins)
13
Sider
13 13
WLS No: BSP/W/13
WORK LOAD DETAILS SHEET
BTM Spinning
Shifts A B C G
Spinning
Activity Description
Ringframe-
LR(432 Spindle)
13
Machine Efficiency: (Sample calculation)
Machine available hours * (Time lost due to doffing,pneumafil bonda,twist contraction
lost,Lot/Count idle spindle) = Machine running hours ( 8 hours * 0.915 = 7.32 hours)
Actual Machine efficiency (%)=Machine Running hours* Running efficiency
EX: For 1728 Spindle Actual machine efficiency (%) = 7.32 hours *0.8497 = 6.219 hours/shift
* Time lost due to doffing,pneumafil bonda,twist contraction lost,Lot/Count idle spindle is
collected from the management
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre
Present
Manpower
-
Designation
Proposed
Manpower
-
Sl.
No
C
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(
%
)
T
o
t
a
l

T
i
m
e

(
M
i
n
s
)
1 1 440 1.5 0.13 13 96.95
2 1 1 1 20.52 13 23.19
3
1 44.2 4.5 0.54 13 121.37
1 44.2 4.5 0.22 13 49.45
1 44.2 4.5 0.40 13 89.90
4
1 0.081 4.5 5.00 13 2.06
1 0.081 4.5 5.00 13 2.06
5
1 0.018 4.5 5.00 13 0.46
1 0.018 4.5 5.00 13 0.46
6
1 15 4.5 0.03 13 2.29
1 15 4.5 0.43 13 32.80
1 15 4.5 0.02 13 1.75
7 1 4 4.5 0.33 13 6.71
A 429.45
B 480
C 89.47%
-
Sider
- -
-
WLS No: BSP/W/13 A
WORK LOAD DETAILS SHEET
BTM Spinning
Shifts A B C G
Spinning
S/F Roving Change
Remove the top clearer, clean and keep on
the lammba
Put the top clearer on the machine after the
count change over
Activity Description
Top clearer cleaning
Ringframe-
Texmaco(440spindle)
Drafting zone cleaning
To attend idle spindles in his m/c
Remove roller lapping using hexablade knife
Piece the broken threads
Bring the S/F roving near the machine from
the S/F roving storage area
Replace the empty rovings with the new
rovings
Place the empty rovings in the area
To collect pnumafil waste and hand over it
to mixing for weighment at the shift end.
Present Utilisation(%)
Roving cut join
Lot change
Count change
Remove the top clearer, clean and keep on
the lammba
Put the top clearer on the machine after the
count change over
Total Workload per Shift ( in man minutes)
Net Available man-mins
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre
Present
Manpower
-
Designation
Proposed
Manpower
-
Sl.
No
C
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S
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/

S
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(
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T
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a
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T
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(
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s
)
-
Sider
- -
-
WLS No: BSP/W/13 A
WORK LOAD DETAILS SHEET
BTM Spinning
Shifts A B C G
Spinning
Activity Description
Ringframe-
Texmaco(440spindle)
5
The running efficiency is calculated using the above formula for different number of drums and
tabulated below:
No of Spindles
Running Efficiency ()
(%)
Operator
workload(%)
The running efficiency is arrived by the formula provided in the research paper : The
Efficiency of N machines Uni-Directionally patrolled by single operative by
Mr.C.Mack,T.Murphy and N.L.Webb,Journal of the Royal Statistical Society, (1957).
2200 (5*440) 81.65% 96.63%
= (b-1) / [ N{K+(b-1)C}]
- 0.0004981, N - 1760(440*4), C - 0.22, K - 0.03
1760 (4*440) 84.76% 82.31%
1980 (4.5*440) 83.18% 89.47%
The above values are depicted in the graph to findout the optimum (where running efficiency &
operative workload meets) number of drums to be alloted per personnel and presented below:
1760 (4*440)
1980
(4.5*440)
2200 (5*440)
Running Efficiency () (%) 84.76% 83.18% 81.65%
Operator workload(%) 82.31% 89.47% 96.63%
70.00%
75.00%
80.00%
85.00%
90.00%
95.00%
100.00%
E
f
f
i
c
i
e
n
c
y
(
%
)
Ringframe-Texmaco
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre
Present
Manpower
-
Designation
Proposed
Manpower
-
Sl.
No
C
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(
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a
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T
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(
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s
)
-
Sider
- -
-
WLS No: BSP/W/13 A
WORK LOAD DETAILS SHEET
BTM Spinning
Shifts A B C G
Spinning
Activity Description
Ringframe-
Texmaco(440spindle)
Remarks:
Speedframe rovings is changed mainly during the lot change and Count change. As the activities are
performed during lot&count change it is being considered under the doffers workload. But small
percentage(30%) of S/F rovings is being changed by sider ( while running).Number of rovings to be
feed per ringframe per shift equals to 50 rovings.
From the graph, the optimum number of spindle can be alloted per operator is 1760 nos
Machine Efficiency: (Sample calculation)
Machine available hours * (Time lost due to doffing,pneumafil bonda,twist contraction
lost,Lot/Count idle spindle) = Machine running hours ( 8 hours * 0.915 = 7.32 hours)
In BTM, there are six number of texmaco machine with 400 spindles are there. As only the number
spindles are less than the 440 spindle texmaco make. The above workload sheet is applicable to that
machines also.
Count Change = 80 / month = 80 / (90 shifts*48 machines) = 0.018 / shift
Lot Change = 350 / month = 350 / (90 shifts*48 machines) =0.0812 / shift
Actual Machine efficiency (%)=Machine Running hours* Running efficiency
EX: For 1760 Spindle Actual machine efficiency (%) = 7.32 hours *0.8476 = 6.204 hours/shift
* Time lost due to doffing,pneumafil bonda,twist contraction lost,Lot/Count idle spindle is collected
from the management
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 6 6
Designation Proposed Manpower 6 6
Sl.
No
Crew
Size
Freq/
Shift
No of
Spindl
es/mac
hine
Basic
Time
(Mins)
Total
Time
(Mins)
1 7 1 5.00 35.00
2
a 5 63 0.48 151.20
b 5 63 440 1.81 570.90
c 5 63 440 0.88 277.20
d 5 63 1.00 315.00
3
a 1 440 0.02 8.80
b 1 440 0.03 11.88
c 1 440 0.04 18.48
d 1 1 3.58 3.58
4
a 1 1.296 440 0.02 10.69
b 1 1.296 440 0.01 7.13
c 1 1.296 440 0.08 48.33
d 1 1.296 440 0.41 233.80
e 1 1.296 440 0.12 68.43
f 1 1.296 440 0.01 7.13
5
a 1 0.296 2 side 1.98 0.59
b 1 0.296 440 0.012 1.55
c 1 0.296 440 0.078 10.13
d 1 0.296 2 side 1.98 0.59
e 1 0.296 440 0.02 2.44
f 1 0.296 440 0.01 1.63
g 1 0.296 440 0.08 10.42
h 1 0.296 440 0.41 53.40
6
G
Spinning
B
Ringframe
WLS No: BSP/W/14
WORK LOAD DETAILS SHEET
BTM Spinning
Shifts A C
Bobbin change(Doffing)
Take trays, Collect the empty R/F bobbins from
storage area near entrance, Reach the machine
spot
Remove the filled R/F bobbin from the spindle &
Put the empty R/F bobbin in the R/F spindle
Keep the collected R/F bobbin trays in the R/F
Sorting area
Piece the roving with the bobbin
Doffer
Activity Description
Shift Release activity
6
Open the doom
Put the new count lammba on the machine
Count Change
Ring Travellour Change
Remove the Old ring travellour
Arrange S/F from racks to trolley
Join the thread roving and bobbin
Bring the S/F roving near the machine from the
S/F roving storage area
Put the S/F roving in the creel
Bring the S/F roving near the machine from the
S/F roving storage area(40 rovings/trolley)
Put the S/F roving in the creel
Join the thread roving and bobbin
Remove the empty S/F bobbins from the creel
and keep near the rack
Move the empty trolley back to S/F rovings area
Remove the lammba for the old count
1
machi
ne/unit
Clean the machine area after ring travellour
change using magnet bar
Put the new ring travellour
Arrange S/F rovings from racks to trolley(40
rovings)
Join the thread after inserting the new ring
Lot Change
Close the doom
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 6 6
Designation Proposed Manpower 6 6
Sl.
No
Crew
Size
Freq/
Shift
No of
Spindl
es/mac
hine
Basic
Time
(Mins)
Total
Time
(Mins)
6
G
Spinning
B
Ringframe
WLS No: BSP/W/14
WORK LOAD DETAILS SHEET
BTM Spinning
Shifts A C
Doffer
Activity Description
6
i 1 0.296 440 0.12 15.63
j 1 0.296 440 0.01 1.63
6
a 1 1 5 9.00 45.00
b 1 1 5 3.01 15.06
c 1 1 5 2.71 13.54
d 1 1 5 2.87 14.36
e 1 1 5 0.99 4.95
f 1 1 900 0.04 34.99
g 1 1 900 0.05 47.82
A 2041.25
B 8
C 2204.55
D 480
E 76.55%
F 6
G 76.55%
Lot Change = 350 / month = 350 / (90 shifts*3 Unit) =1.296 / shift/unit
As reliever is provided, net available man mins becomes 480 mins. As the above activity
frequency is for 480 mins.
Clean the creel plastic cover top area for fly
Spindle gap cleaning
Jockey pulley cleaning
Clean using the broom stick
Remove the empty S/F bobbins from the creel
and keep near the rack
Move the empty trolley back to S/F rovings area
Cleaning
Clean the creels (below the cover) area for fly
One Doffing team consist 6 Doffers and one Co-ordinating person.Each unit have one doffing
team.
Rest & Relaxation Allowances ( % )(Total-13%-5% relieved by reliever+8%
added in the workload)
Total Workload ( in man minutes )
Net Available man-mins
No of rovings consumed per shift/unit = 900 nos ( from machine capacity)
Ring travellour Change -1 machine/ shift / unit
Basic Workload per Shift ( in man minutes)
The doffers maximum workload is on Texmaco 440 spindle machine comapred to 400
spindle(texmaco) and LR (432 Spindle). Hence it has taken for calculation and shown above.
Present Utilisation(%)
Proposed Manpower per shift
Clean the S/F empty rovings(using knife remove
the threads)
Arrange the cleaned S/F empty rovings in the
racks
Count Change = 80 / month = 80 / (90 shifts*3 Unit) = 0.296 / shift/ unit
Proposed Utilisation(%)
Remarks:
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 3 3 3 -
Designation Proposed Manpower 3 3 3 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total Time
(Mins)
1
1 1 5.00 5.00
2
1 3 63.00 189.00
3
4
5
A 194.00
B 13
C 219.22
D 450
E 48.72%
F 1
G 48.72%
B C G
Spinning
Ringframe
Doffer-Leader
Activity Description
Shift Release activity
WLS No: BSP/W/15
WORK LOAD DETAILS SHEET
BTM Spinning
Shifts A
The above activitiy(3,4 &5) is supervisory in nature.
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Relieve the Ringframe sider in that unit(Tea,Lunch
Or breaks)
Co-ordinate the doffing team effectively for
minimising the machine downtime for changover
Remarks:
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Discussing with the supervisors, siders
Monitor and perform the scheduled activities like ring
travellours change, machine cleaning and lot
change/count change with the doffers
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 3 3 3 -
Designation Proposed Manpower 3 3 3 -
Sl.
No
Crew
Size
Freq /
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 6 63 375.00
A 375.00
B 13
C 423.75
D 450
E 94.17%
F 1
G 94.17%
WLS No: BSP/W/16
WORK LOAD DETAILS SHEET
BTM Spinning
Shifts A B C G
Spinning
Proposed Manpower per shift
Proposed Utilisation(%)
Remarks:
Lunch-30 mins, Tea - 10 mins, Personal Intervention(5%) - 23 mins . Total - 63 mins/shift/person
Activity Description
Relieve the ringframe-doffers for breaks
Present Utilisation(%)
Ringframe
Reliever-Doffers
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Net Available man-mins
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 1 1 1 -
Designation Proposed Manpower 1 1 1 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
1 96 93.12 93.12
2 1 6 120.00 120.00
3
1 1 90.00 90.00
A 303.12
B 13
C 342.53
D 360
E 95.15%
F 1
G 95.15%
G
RINGFRAME
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
WLS No: BSP/W/17
WORK LOAD DETAILS SHEET
BTM
Shifts A B C
RINGFRAME
RUNNING FITTER
Activity Description
Check the ratched pawl of all the ringframe and TFO
machines
Change the machine particular as per the requirement
Attend the ringframe & TFO idle spindle due to
mechanical faults
Total Workload ( in man minutes )
Net Available man-mins
Proposed Manpower per shift
Proposed Utilisation(%)
Remarks:
Present Utilisation(%)
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 1 1 1 -
Designation Proposed Manpower 2 2 2 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
1 1 62.50 62.50
2 1 4 20.00 20.00
3
1 1 65.00 65.00
4 1 3 22.17 66.50
5
1 3 36.00 36.00
6
1 3 15.00 45.00
7
1 1 30.00 30.00
8 1 3 31.67 95.00
9 1 2 15.00 30.00
A 450.00
B 13
C 508.50
D 450
E 113.00%
F 2
G 56.50%
Basic Workload per Shift ( in man minutes)
Proposed Utilisation(%)
Remarks:
Check the finisher drawframe wrapping
Give the lot information (New lot & Final Lot) to
the post spinning secetion
Check the lot final ringframe bobbins
Check the wrapping of the new lot taken at
ringframe
Take the sample from carding & ringframe and
paste them at the ringframe sample book
Complete the sample book from mixing layering
register
Check material for contamination
Hank Reading
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
RING FRAME
CHECKER
Activity Description
Check the running shade from blowroom to
ringframe
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
WLS No: BSP/W/18
WORK LOAD DETAILS SHEET
BTM
Shifts A B C G
RING FRAME
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 3 3 3 -
Designation Proposed Manpower 3 3 3 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
1 1 10.50 10.50
2
1 3 46.80 46.80
3 1 4 128.00 128.00
4
1 2 52.00 52.00
5
1 1 31.20 31.20
A 268.50
B 13
C 303.41
D 450
E 67.42%
F 1
G 67.42%
Proposed Manpower per shift
Proposed Utilisation(%)
Remarks:
Three floor cleaner is recommended in ringframe section of BTM. The above workload sheet is for
one floor cleaner.
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Collect the ringframe bobbins from the auto winding
colour wise
Floor cleaning
Help the sider in replacing the empty simplex bobbin
with the full rove bobbin. (if Simplex bobbins
replacement are higher than 100)
Sort the ringframe waste shade wise and take the
sweeping waste to the blowroom section at the end of
the shift.
Basic Workload per Shift ( in man minutes)
Net Available man-mins
Present Utilisation(%)
Activity Description
Check the cleaning of the department at the shift start
WLS No: BSP/W/19
WORK LOAD DETAILS SHEET
BTM
Shifts A B C G
RINGFRAME
RINGFRAME
FLOOR CLEANER
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 2 2 2 -
Designation Proposed Manpower 1 1 1 -
Sl.
No
Crew
Size
Freq /
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 4 63 252.00
2
1 2 10 20.00
3
1 16 0.90 14.40
4
1 16 1.00 16.00
5
1 8 2.12 16.96
6
1 8 0.67 5.36
7
1 8 0.97 7.75
8
1 8 0.67 5.36
9
1 16 2.00 32.00
A 369.83
B 13
C 417.91
D 450
E 46.43%
F 1
G 92.87%
Lunch-30 mins, Tea - 10 mins, Personal Intervention(5%) - 23 mins . Total - 63 mins/shift/person
No of doffs- 4 per shift per machine
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Remarks:
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Come back to workplace
Bring the empty autocone from the rack and arrange it
on the machine(60 cone/time)(two machine/reliever)
Move the trolley to loose packing area
Arrange the cones from trolley to ground
Basic Workload per Shift ( in man minutes)
Maintain sample book for that particular machine(two
machine/reliever)
Take the full bobbins/half bobbins and put on the
autoconer tenter trays
Arrange the trays after&before segregation
Collect the full autocone from the machine and arrange
it on the trolley(60 cones/trolley)( One
machine/reliever)
Autoconer
Reliever
Activity Description
Relieve - Four tenter's for breaks
WLS No: BSP/W/20
WORK LOAD DETAILS SHEET
BTM Spinning
Shifts A B C G
Post Spinning
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 2 2 2
Designation Proposed Manpower 2 2 2
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
1 62 56.42 112.84
2 1 1 60.00 120.00
A 232.84
B 13
C 263.11
D 450
E 58.47%
F 2
G 58.47%
Present Utilisation(%)
Proposed Manpower per shift
Total Workload ( in man minutes )
Net Available man-mins
Proposed Utilisation(%)
Remarks:
To relieve 2 autowinding tenters for lunch
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
WINDING
MATERIAL MAN
Activity Description
To feed full R/F bobbins to auto winding m/cs
during the shift using trolleys ( 62 doffs per shift for
one material man)
WLS No:BSP/W/21
WORK LOAD DETAILS SHEET
BTM
Shifts A B C G
POST SPG
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 2 2 2 -
Designation Proposed Manpower 2* 2* 2* -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1
24000
bobbins
120.00 240.00
2 1
1200
bobbins
16.20 32.40
3 1
300
bobbins
105.00 210.00
A 482.40
B 13
C 545.11
D 450
E 60.57%
F 2
G 60.57%
Mending of workable bottoms rejected by 3 A/C
m/c and handing them to A/C operators.(300
bobbins/kirchiman)
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Net Available man-mins
Proposed Manpower per shift
Proposed Utilisation(%)
Remarks:
Activity Description
Sorting empty bobbins into tapas (3 A/C m/c per
kirchi man)(24000 bobbins / kirchiman)
Cutting kirchi of 3 A/C m/c(1200 bobbins/kirchi
man)
Present Utilisation(%)
POST SPG
B C G
WINDING
KIRCHI MAN
WLS No: BSP/W/22
WORK LOAD DETAILS SHEET
BTM
Shifts A
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 1
Designation Proposed Manpower - - - 1
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 5 57.50 57.50
2
1
70
trolleys/
day
249.90 249.90
A 307.40
B 13
C 347.36
D 480
E 72.37%
F 1
G 72.37%
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Collect trolleys from the dept.
Remarks:
AUTOWINDING
Cutting the trolley Jam
Basic Workload per Shift ( in man minutes)
G
AUTOWINDING
JAM CUTTER
Activity Description
Rest & Relaxation Allowances ( % )
WLS No: BSP/W/23
WORK LOAD DETAILS SHEET
BTM
Shifts A B C
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 1
Designation Proposed Manpower - - - 1
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
1
100
cones
159.29 159.29
2
1
256
cones
24.92 24.92
3
1
100
bobbins
64.00 64.00
4
1
98
cones
53.10 53.10
5
1
20
cones
26.55 26.55
6
1
2
lots(2kg
)
17.70 17.70
7
1
15
cones
17.70 17.70
8
1
72
cones
26.55 26.55
A 389.80
B 13
C 440.48
D 480
E 91.77%
F 1
G 91.77%
Remarks:
Proposed Manpower per shift
Rewinding of SQC tested TFO cones
Processing of TFO broken tape, zero TPI(at top) to
2nd quality
Preparation of pair of final single cone
Rewinding of single cones to remove jali, double
etc
Rewinding of classimate cones
Present Utilisation(%)
Net Available man-mins
Shifting of production of 1 savio m/c to packing
section
Processing of defective bobbins(R/F) for 2nd
quality
Proposed Utilisation(%)
G
POST SPG
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Rewinding of packing rejection
WINDING
REWINDER
Activity Description
WLS No: BSP/W/24
WORK LOAD DETAILS SHEET
BTM
Shifts A B C
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 2 2 2 -
Designation Proposed Manpower 2 2 2 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
1
6
rounds
127.80 127.80
2 1 1 8.85 8.85
3
1 0.33 3.30 3.30
4
1
1200
cones
14.40 14.40
5
1
20
pillers
& 40
tube
lights
38.80 38.80
A 193.15
B 13
C 218.26
D 450
E 48.50%
F 2
G 48.50%
Basic Workload per Shift ( in man minutes)
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Remarks:
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
To shift sweeping of the shift to waste godown
To shift hard waste of all the three shift to waste
godown
To clean cheese winding empty cones and place in
racks colorwise
To clean tube lights and pillers falling in one's floor
area.
POST SPG
FLOOR CLEANER
Activity Description
To sweep area of post spg section
WLS No: BSP/W/25
WORK LOAD DETAILS SHEET
BTM
Shifts A B C G
POST SPG
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 1 1 1 -
Designation Proposed Manpower 1 1 1 -
Sl.
No
Crew
Size
Freq /
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 2 63 126.00
2
1 6454 0.01200 77.45
3
1 16 0.90 14.40
4
1 16 1.00 16.00
5
1 4 2.12 8.48
6
1 4 0.67 2.68
7
1 4 0.97 3.88
8
1 4 0.67 2.68
9
1 4 2.00 8.00
10
1 4 3.00 12.00
A 271.56
B 13
C 306.87
D 450
E 68.19%
F 1
G 68.19%
Lunch-30 mins, Tea - 10 mins, Personal Intervention(5%) - 23 mins . Total - 63 mins/shift/person
No of bobbins - 6146 Bobbins /shift + 5% rejection (308 bobbins/shift) = 6454 bobbins/shift
Collect the full autocone from the machine and arrange
it on the trolley(60 cones/trolley)
Arrange the cones from trolley to ground
Bring the empty autocone from the rack and arrange it
on the machine(60 cone/time)
Bring R/F bobbins from the R/F area
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Proposed Utilisation(%)
Remarks:
Arrange the trays after&before segregation
Move the trolley to loose packing area
Come back to workplace
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Relieve-Two tenter's for breaks
Proposed Manpower per shift
Post Spinning
Sort the bobbins(only in machine 7)
Take the full bobbins/half bobbins and put on the
autoconer tenter trays
Autconer-Savio No 7
Helper
Activity Description
WLS No: BSP/W/26
WORK LOAD DETAILS SHEET
BTM Spinning
Shifts A B C G
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 16 16 -
Designation Proposed Manpower 8 8 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Allow
ance
(%)
Total
Time
(Mins)
1
1 30.25 0.50 13 17.09
2 1 3025 0.030 13 102.55
3 1 991.2 0.09 13 100.81
4
1 84 0.10 13 9.49
5
1 2 2.00 13 4.52
A 234.46
B 480
C 48.84%
5
Spinning
Autoconer 16
Winder 8
Collect the R/F bobbins from the trolley to
trays
Put the R/F Bobbins in the machine drum
Attend the idle drums
Take the empty auto cone from the machine
tray, remove the filled cone and put the empty
cone on the machine and start the machine
Basic Workload per Shift ( in man minutes)
WLS No: BSP/W/27
WORK LOAD DETAILS SHEET
BTM
Shifts A B C G
Activity Description
Collect the waste from the machine
40 98.87% 64.81%
Net Available man-mins
Present Utilisation(%)
The running efficiency is arrived by the formula provided in the research paper : The
Efficiency of N machines Uni-Directionally patrolled by single operative by
Mr.C.Mack,T.Murphy and N.L.Webb,Journal of the Royal Statistical Society, (1957).
= (b-1) / [ N{K+(b-1)C}]
- 0.097943723, N - 30, C - 0.09, K - 0.2
30 99.96% 48.84%
The running efficiency is calculated using the above formula for different number of drums
and tabulated below:
No of Drums Running Efficiency () (%) Operator workload(%)
50 97.11% 80.78%
60 94.90% 96.74%
64 93.90% 103.13%
70 92.30% 112.71%
The above values are depicted in the graph to findout the optimum (where running efficiency
& operative workload meets) number of drums to be alloted per personnel and presented
below:
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 16 16 -
Designation Proposed Manpower 8 8 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Allow
ance
(%)
Total
Time
(Mins)
Spinning
Autoconer 16
Winder 8
WLS No: BSP/W/27
WORK LOAD DETAILS SHEET
BTM
Shifts A B C G
Activity Description
* Time lost due to general cleaning,hardwaste removal,splicing is collected from the management
From the graph, the optimum number of drums can be alloted per operator is 60 nos
Remarks:
For 60 drums, Number of bobbins required - 5762 Bobbins/shift
Rejection (5%) - 5762 * 5% = 288 bobbins.For 30 drums -(5762+288) /2 = 3025 bobbins/30
drums/shift.
Machine Efficiency: (Sample calculation)
Machine available hours * (Time lost due general cleaning,hardwaste removal,splicing) = Machine
running hours ( 8 hours * 77 % = 6.16 hours)
Actual Machine efficiency (%)=Machine Running hours* Running efficiency
EX: For 60 drums, Actual machine efficiency (%) = 6.16 hours *0.9490 =5.845 hours/shift
30 40 50 60 64 70
Running Efficiency ()
(%)
99.96% 98.87% 97.11% 94.90% 93.90% 92.30%
Operator workload(%) 48.84% 64.81% 80.78% 96.74% 103.13%112.71%
0.00%
20.00%
40.00%
60.00%
80.00%
100.00%
120.00%
E
f
f
i
c
i
e
n
c
y
(
%
)
Autoconer
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre
Present
Manpower
10 -
Designation
Proposed
Manpower
7 -
Sl.
No
Crew
Size
Freq/
Shift/
spindle
No of
spind
les
Basic
Time
(Mins)
Allow
ance
(%)
Total
Time
(Mins)
1
1 1.68 64 0.0663 13 8.06
2
1 1.68 64 0.1500 13 18.22
3
1 1.68 64 0.0663 13 8.06
4
1 1.68 64 0.0657 13 7.98
5
1 1.68 64 0.3650 13 44.35
6
1 3.36 64 0.0440 13 10.69
7 1 3.36 64 0.1060 13 25.76
8 1 3.36 64 0.0369 13 8.97
9
1 3.36 64 0.0500 13 12.15
10
1 3.36 64 0.0092 13 2.23
11
1 3.36 64 0.0083 13 2.02
12 1 2.688 64 0.280 13 54.43
13 1 1 1 15.000 13 16.95
A 219.87
B 480
C 45.81%
5
WLS No: BSP/W/28
WORK LOAD DETAILS SHEET
BTM Spinning
Shifts A B C G
Post Spinning
Cheesewinding 10 10
Tenter 7 7
Basic Workload per Shift ( in man minutes)
Activity Description
Move the empty trolley to loose packing
area
Put the full autocone from ground to trolley
Move the trolley to Cheesewinding section
Keep the autocone from trolley to machine
table
Replace the empty autocone with full
autocone&join
Bring the empty cheese cone from the
rack&keep on the machine
Replace the full cheese cone with empty
cheese cone
Put the sticker on the cheese cone
Collect full cheese cone from machine table
and keep on trolley
Move the trolley to weighing machine &
Weigh the trolley
Move the trolley to respective count running
TFO machine area
Attend the thread break
Clean the machine
Net Available man-mins
Present Utilisation(%)
The running efficiency is calculated using the above formula for different number of drums
and tabulated below:
No of Drums
Running Efficiency ()
(%)
Operator
workload(%)
The running efficiency is arrived by the formula provided in the research paper : The
Efficiency of N machines Uni-Directionally patrolled by single operative by
Mr.C.Mack,T.Murphy and N.L.Webb,Journal of the Royal Statistical Society, (1957).
= (b-1) / [ N{K+(b-1)C}]
- 0.007308, N - 64, C - 0.28, K - 0.05
64 89.34% 45.81%
76 87.59% 49.77%
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre
Present
Manpower
10 -
Designation
Proposed
Manpower
7 -
Sl.
No
Crew
Size
Freq/
Shift/
spindle
No of
spind
les
Basic
Time
(Mins)
Allow
ance
(%)
Total
Time
(Mins)
WLS No: BSP/W/28
WORK LOAD DETAILS SHEET
BTM Spinning
Shifts A B C G
Post Spinning
Cheesewinding 10 10
Tenter 7 7
Activity Description
In BTM Spinning, the four cheese winding machines are in one section and two machines are
in unit-3. Based on the above findings, two personnel is recommended for unit-3 machines(2
nos) and five personnel for four machines in the unit-1 &2.
Machine Efficiency: (Sample calculation)
Machine available hours * (Time lost due to doffing,worker's lunch,cleaning,Lot/Count change and
idle ) = Machine running hours ( 8 hours * 77.5 % = 6.2 hours)
Actual Machine efficiency (%)=Machine Running hours* Running efficiency
80 87.02% 56.38%
90 85.63% 62.98%
80.49% 89.40%
100 84.28% 69.59%
110 82.98% 76.19%
The above values are depicted in the graph to findout the optimum (where running efficiency &
operative workload meets) number of drums to be alloted per personnel and presented below:
From the graph, the optimum number of drum can be alloted per operator is 120 nos.
Remarks:
120 81.71% 82.80%
130
64 76 80 90 100 110 120 130
Running Efficiency () (%) 89.34% 87.59% 87.02% 85.63% 84.28% 82.98% 81.71% 80.49%
Operator workload(%) 45.81% 49.77% 56.38% 62.98% 69.59% 76.19% 82.80% 89.40%
0.00%
10.00%
20.00%
30.00%
40.00%
50.00%
60.00%
70.00%
80.00%
90.00%
100.00%
E
f
f
i
c
i
e
n
c
y
(
%
)
Cheesewinding
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre
Present
Manpower
10 -
Designation
Proposed
Manpower
7 -
Sl.
No
Crew
Size
Freq/
Shift/
spindle
No of
spind
les
Basic
Time
(Mins)
Allow
ance
(%)
Total
Time
(Mins)
WLS No: BSP/W/28
WORK LOAD DETAILS SHEET
BTM Spinning
Shifts A B C G
Post Spinning
Cheesewinding 10 10
Tenter 7 7
Activity Description
60 60 60 60 80 40 40 76 76
1
60 60 44 44
As per the breakage data provided by the company,there is no difference in breaks frequency among
different makes(Textool,PSFMK and RJK) and very negligible difference in elemental times.Hence,
the above workload is provided and applicable for all makes.
At present, the operator's stops the machine during lunch break. Same practice is being
proposed.Based on the above condition, reliever is not provided.
EX: For 120 drums Actual machine efficiency (%) = 6.2 hours *0.8171 = 5.066 hours/shift
Unit 1 &2
* Time lost due to doffing,worker's lunch,cleaning,Lot/Count change and idle is collected from the
management
Unit 3
80
Proposed manpower deployment is as follows: (each colour represents one personnel)
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 1 1 1 -
Designation Proposed Manpower 1 1 1 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 1 25.00 25.00
2 1 1 40.00 40.00
3 1 1 20.00 20.00
4
1 1 55.83 55.83
5
1 11 55.00 55.00
6
1 1 42.40 42.40
7
1 3-4 30.00 30.00
8 1 1 30.00 30.00
A 298.23
B 13
C 337.00
D 450
E 74.89%
F 1
G 74.89% Proposed Utilisation(%)
Remarks:
Proposed Manpower per shift
To adjust savio drums according to ringframe
color bobbins working in R/F section and make a
record of it with the help of savio relievers.
To adjust cheese winding drums as per programme
decided by shift incharge with the help of cheese
winders
To weigh the doffs of each cheese winder on
weighing scales one for Unit 1 and second for Unit
3. Record the cheese winder's production details in
production register.
To receive info. Regarding lot final from ring
frame during his shift from shift incharge then get
lot final data in sample book of that unit.
Idle spindle count
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
G
POST SPG
Total Workload ( in man minutes )
To take shift charge
Present Utilisation(%)
Net Available man-mins
To engage hands in the dept as per requirement
To identify hands shortage section wise
POST SPG
JOBBER
Activity Description
WLS No: BSP/W/30
WORK LOAD DETAILS SHEET
BTM
Shifts A B C
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 2 2 2 -
Designation Proposed Manpower 2 2 2 -
Sl.
No
Crew
Size
Freq /
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 10 63 630.00
2
1 1 10.00 10.00
3
1 30 0.54 16.08
4
1 30 2.36 70.80
5
1 30 0.54 16.20
6
1 30 1.16 34.80
A 777.88
B 12
C 871.23
D 450
E 96.80%
F 2
G 96.80%
No of trolleys = (37.28 cones / machine / shift) * 48 machines = 1790 cones/shift = 1790 / 60
cone/trolley = 30 trolleys
Proposed Utilisation(%)
Remarks:
Lunch-30 mins, Tea - 10 mins, Personal Intervention(5%) - 23 mins . Total - 63 mins/shift/person
TFO
Reliever-Tenter
Activity Description
Relieve-Ten TFO tenter's for breaks(5 persons each)
Proposed Manpower per shift
Present Utilisation(%)
Total Workload ( in man minutes )
Net Available man-mins
Collect the hard waste and handover & inform to
supervisor
Collect full TFO Cones from the machine table, keep it
on the trolley(60 nos/trolley)
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Move the full TFO Cones trolley back to packing
room(60 nos/trolley)
Bring the empty trolley from packing to respective
TFO machine(mean distance)
Arrange the TFO cones from trolley to ground floor
WLS No: BBSP/W/31
WORK LOAD DETAILS SHEET
BTM Spinning
Shifts A B C G
Post Spinning
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 1
Designation Proposed Manpower - - - 1
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
1
80
cones
165.00 165.00
2
1 7 lots 40.00 40.00
3
1 10 lots 20.00 20.00
4
1 10 lots 38.33 38.33
5
1 7 lots 14.00 14.00
6
1
30
cones
8.20 8.20
7
1
8-10
cones
15.00 15.00
8
1 2 25.67 25.67
A 326.20
B 13
C 368.61
D 480
E 76.79%
F 1
G 76.79% Proposed Utilisation(%)
Remarks:
Proposed Manpower per shift
Lot run out from cheese winding section and record
it in dept. sample book
Lot final info. To packing after the lot final from
TFO by writing in packing sample book
Collection of defective cones from dept. for
mending accordingly
Baby cones of all new lots taken last day to yarn
development dept.
Checking for loose packing for savio final lots ,
shifted to cheese winding if found faulty.
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
G
POST SPG
Total Workload ( in man minutes )
Shifting of packing rejection cones to manual
winding m/c
Present Utilisation(%)
Net Available man-mins
New lot information in packing sample book by
writing lot no. shade no.
Lot run out from TFO section and record it in dept.
sample book
POST SPG
CHECKER
Activity Description
WLS No: BSP/W/32
WORK LOAD DETAILS SHEET
BTM
Shifts A B C
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre
Present
Manpower
12 -
Designation
Proposed
Manpower
12 -
Sl.
No
C
r
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w

S
i
z
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F
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/

S
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m
a
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i
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B
a
s
i
c

T
i
m
e

(
M
i
n
s
)
A
l
l
o
w
a
n
c
e

(
%
)
T
o
t
a
l

T
i
m
e

(
M
i
n
s
)
1
1 78.3 4 0.0762 13 26.96
2
1 78.3 4 0.5500 13 194.73
3
1 78.3 4 0.0706 13 24.98
4 1 39.2 4 0.0235 13 4.16
5 1 39.2 4 0.0157 13 2.78
6
1 39.2 4 0.2600 13 46.02
7 1 156 4 0.0314 13 22.11
8 1 18 4 0.4000 13 32.57
9 1 1 1.5 20.0 13 30.00
A 384.32
B 480
C 80.07%
5
WLS No: BSP/W/33
WORK LOAD DETAILS SHEET
BTM Spinning
Shifts A B C G
Post Spinning
Put the operator slip on the cone
Attend the thread cut
12 12
Activity Description
Bring empty TFO cone from the cone room
Keep the cones on the machine
Remove the full TFO cone,place on the
machine holder & keep empty paper
cone&join
TFO-VJ(156
Spindles/ Machine)
12 12
Bring the cheese winding cone from the
storage area, arrange on the machine
table,keep the empty trolley aside(per cone)
Replace the empty cheese cone with the full
cheese cone & keep the empty cheese on the
machine table& tie
Collect the empty cheese cone and arrange it
on the rack colourwise
TENTER
Clean the machine
Basic Workload per Shift ( in man minutes)
The running efficiency is calculated using the above formula for different number of drums and
tabulated below:
Net Available man-mins
Present Utilisation(%)
The running efficiency is arrived by the formula provided in the research paper : The
Efficiency of N machines Uni-Directionally patrolled by single operative by
Mr.C.Mack,T.Murphy and N.L.Webb,Journal of the Royal Statistical Society, (1957).
= (b-1) / [ N{K+(b-1)C}]
- 0.000253326, N - 624 (156*4), C - 0.4, K - 0.07
No of Spindles
Running Efficiency ()
(%)
Operator
workload(%)
624 (4 *156) 94.54% 80.07%
702 (4.5*156) 93.90% 89.72%
780 (5*156) 93.27% 98.08%
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre
Present
Manpower
12 -
Designation
Proposed
Manpower
12 -
Sl.
No
C
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S
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(
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A
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(
%
)
T
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a
l

T
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(
M
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n
s
)
WLS No: BSP/W/33
WORK LOAD DETAILS SHEET
BTM Spinning
Shifts A B C G
Post Spinning
12 12
Activity Description
TFO-VJ(156
Spindles/ Machine)
12 12
TENTER
858 (5.5*156) 92.65% 109.19%
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre
Present
Manpower
12 -
Designation
Proposed
Manpower
12 -
Sl.
No
C
r
e
w

S
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F
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/

S
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B
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c

T
i
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(
M
i
n
s
)
A
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l
o
w
a
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e

(
%
)
T
o
t
a
l

T
i
m
e

(
M
i
n
s
)
WLS No: BSP/W/33
WORK LOAD DETAILS SHEET
BTM Spinning
Shifts A B C G
Post Spinning
12 12
Activity Description
TFO-VJ(156
Spindles/ Machine)
12 12
TENTER
168 168 168 168 168 168 168 168 168 168
It is only suggested,actual deployment may be changed based on the machine efficiency required
.As in Unit1 &2 Different shades are running, allocation of common person leads to quality
problem. Hence separate personnel is being recommended,
Remarks:
Collection of full TFO cones from machine table to trolley is performed by doffers
Machine Efficiency: (Sample calculation)
Machine available hours * (Time lost due to twist contraction and idle spindle) = Machine running
hours ( 8 hours * 97 % = 7.76 hours)
The above values are depicted in the graph to findout the optimum (where running efficiency &
operative workload meets) number of drums to be alloted per personnel and presented below:
From the graph, the optimum number of drum can be alloted per operator is 624 nos
Actual Machine efficiency (%)=Machine Running hours* Running efficiency
EX: For 624 spindles, Actual machine efficiency (%) = 7.76 hours *0.9454 = 7.336 hours/shift
* Time lost due to general cleaning,count/lot change,idle and maintenance cleaning,breakdown is
collected from the management
624 (4 *156)
702
(4.5*156)
780 (5*156)
858
(5.5*156)
Running Efficiency () (%) 94.54% 93.90% 93.27% 92.65%
Operator workload(%) 80.07% 89.72% 98.08% 109.19%
0.00%
20.00%
40.00%
60.00%
80.00%
100.00%
120.00%
E
f
f
i
c
i
e
n
c
y
(
%
)
TFO-VJ (156 Spindles)
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre
Present
Manpower
12 -
Designation
Proposed
Manpower
12 -
Sl.
No
C
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WLS No: BSP/W/33
WORK LOAD DETAILS SHEET
BTM Spinning
Shifts A B C G
Post Spinning
12 12
Activity Description
TFO-VJ(156
Spindles/ Machine)
12 12
TENTER
VJ VJ VJ VJ VJ VJ VJ VJ VJ VJ
144 144 144 144 144 156 156 156 156 144 144
VJ P p p p VJ Vj VJ Vj P P
144 144 144 144 156 156 156 156 144 144 144 144
P P P P VJ VJ Vj Vj VJ VJ VJ VJ
144 144 144 144 144 144 144 144 144 144
VJ VJ VJ VJ VJ VJ VJ VJ VJ VJ
144 144 144 140 140
VJ VJ VJ VJ VJ
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre
Present
Manpower
-
Designation
Proposed
Manpower
-
Sl.
No
Crew
Size
Freq/
Shift
No of
machi
ne
Basic
Time
(Mins)
Allow
ance(
%)
Total
Time
(Mins)
1
1 83.48 4 0.0762 13 28.74
2
1 83.48 4 0.5500 13 207.53
3
1 83.48 4 0.0706 13 26.62
4 1 41.74 4 0.0235 13 4.44
5 1 41.74 4 0.0157 13 2.96
6
1 41.74 4 0.2600 13 49.05
7 1 168 4 0.0314 13 23.81
8 1 18.01 4 0.4000 13 32.57
9 1 1 1.5 20.0 13 30.00
A 405.72
B 480
C 84.53%
5
756 (4.5*168) 93.64%
840 (5*168) 92.98% 104.09%
The above values are depicted in the graph to findout the optimum (where running efficiency
& operative workload meets) number of drums to be alloted per personnel and presented
below:
94.31% 84.53%
The running efficiency is arrived by the formula provided in the research paper : The
Efficiency of N machines Uni-Directionally patrolled by single operative by
Mr.C.Mack,T.Murphy and N.L.Webb,Journal of the Royal Statistical Society, (1957).
- 0.0002461, N - 672 (168*4), C - 0.4, K -0.07
672 (4 *168)
The running efficiency is calculated using the above formula for different number of drums
and tabulated below:
No of Spindles
Basic Workload per Shift ( in man minutes)
Running Efficiency ()
(%)
Operator
workload(%)
94.31%
Attend the thread cut
Clean the machine
Net Available man-mins
Present Utilisation(%)
Bring empty TFO cone from the cone room
Keep the cones on the machine
Remove the full TFO cone,place on the
machine holder & keep empty paper
cone&join
Put the operator slip on the cone
Activity Description
Bring the cheese winding cone from the
storage area, arrange on the machine
table,keep the empty trolley aside(per cone)
Replace the empty cheese cone with the full
cheese cone & keep the empty cheese on the
machine table& tie
Collect the empty cheese cone and arrange
it on the rack colourwise
Post Spinning
TFO-VJ(168
Spindles/ Machine)
- -
TENTER
- -
WLS No: BSP/W/33 A
WORK LOAD DETAILS SHEET
BTM Spinning
Shifts A B C G
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre
Present
Manpower
-
Designation
Proposed
Manpower
-
Sl.
No
Crew
Size
Freq/
Shift
No of
machi
ne
Basic
Time
(Mins)
Allow
ance(
%)
Total
Time
(Mins)
Activity Description
Post Spinning
TFO-VJ(168
Spindles/ Machine)
- -
TENTER
- -
WLS No: BSP/W/33 A
WORK LOAD DETAILS SHEET
BTM Spinning
Shifts A B C G
Collection of full TFO cones from machine table to trolley is performed by doffers
Remarks:
From the graph, the optimum number of drum can be alloted per operator is 672 nos
Machine available hours * (Time lost due to twist contraction and idle spindle) = Machine running
hours ( 8 hours * 97 % = 7.76 hours)
Actual Machine efficiency (%)=Machine Running hours* Running efficiency
EX: For 672 spindles, Actual machine efficiency (%) = 7.76 hours *0.9431 = 7.31 hours/shift
Machine Efficiency: (Sample calculation)
* Time lost due to general cleaning,count/lot change,idle and maintenance cleaning,breakdown is
collected from the management
672 (4 *168) 756 (4.5*168) 840 (5*168)
Running Efficiency () (%) 94.31% 93.64% 92.98%
Operator workload(%) 84.53% 94.31% 104.09%
0.00%
20.00%
40.00%
60.00%
80.00%
100.00%
120.00%
E
f
f
i
c
i
e
n
c
y
(
%
)
TFO-VJ(168 Spindles)
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre
Present
Manpower
-
Designation
Proposed
Manpower
-
Sl.
No
Crew
Size
Freq/
Shift
No of
machi
ne
Basic
Time
(Mins)
Allowa
nce
(%)
Total
Time
(Mins)
1
1 71.56 4 0.0680 13 21.99
2
1 71.56 4 0.5355 13 173.21
3
1 71.56 4 0.0690 13 22.32
4 1 35.78 4 0.0210 13 3.40
5 1 35.78 4 0.0140 13 2.26
6
1 35.78 4 0.2400 13 38.81
7 1 144 4 0.0280 13 18.22
8 1 16.46 4 0.5355 13 39.84
9 1 1 1.5 20.0 13 20.00
A 340.06
B 480
C 70.85%
5
WLS No: BSP/W/33 B
WORK LOAD DETAILS SHEET
BTM Spinning
Shifts A B C G
Post Spinning
Remove the full TFO cone,place on the
machine holder & keep empty paper
cone&join
Put the operator slip on the cone
TFO-
PRERNA(144
Spindle/Machine)
- -
TENTER - -
Activity Description
Bring the cheese winding cone from the
storage area, arrange on the machine
table,keep the empty trolley aside(per
cone)
Replace the empty cheese cone with the
full cheese cone & keep the empty cheese
on the machine table& tie
Collect the empty cheese cone and
arrange it on the rack colourwise
Bring empty TFO cone from the cone
room
Keep the cones on the machine
Net Available man-mins
Present Utilisation(%)
Attend the thread cut
Clean the machine
Basic Workload per Shift ( in man minutes)
648 (144*4.5) 92.51% 81.66%
Operator workload(%)
The running efficiency is arrived by the formula provided in the research paper : The
Efficiency of N machines Uni-Directionally patrolled by single operative by
Mr.C.Mack,T.Murphy and N.L.Webb,Journal of the Royal Statistical Society, (1957).
= (b-1) / [ N{K+(b-1)C}]
- 0.00025, N - 576 (144*4), C - 0.535, K - 0.07
576 (144*4) 93.29% 70.85%
The running efficiency is calculated using the above formula for different number of drums
and tabulated below:
No of Drums
Running Efficiency
() (%)
720 (144*5) 91.75% 90.03%
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre
Present
Manpower
-
Designation
Proposed
Manpower
-
Sl.
No
Crew
Size
Freq/
Shift
No of
machi
ne
Basic
Time
(Mins)
Allowa
nce
(%)
Total
Time
(Mins)
WLS No: BSP/W/33 B
WORK LOAD DETAILS SHEET
BTM Spinning
Shifts A B C G
Post Spinning
TFO-
PRERNA(144
Spindle/Machine)
- -
TENTER - -
Activity Description
792 (144*5.5) 91.00% 98.41%
Remarks:
Collection of full TFO cones from machine table to trolley is performed by relievers
864 (144*6) 90.26% 106.79%
The above values are depicted in the graph to findout the optimum (where running efficiency
& operative workload meets) number of drums to be alloted per personnel and presented
below:
From the graph, the optimum number of spindle can be alloted per operator is 720 nos
Machine Efficiency: (Sample calculation)
Machine available hours * (Time lost due to twist contraction and idle spindle) = Machine running
hours ( 8 hours * 97 % = 7.76 hours)
Actual Machine efficiency (%)=Machine Running hours* Running efficiency
EX: For 720 spindles, Actual machine efficiency (%) = 7.76 hours *0.9175 = 7.119 hours/shift
* Time lost due to general cleaning,count/lot change,idle and maintenance cleaning,breakdown is
collected from the management
576 (144*4)
648
(144*4.5)
720 (144*5)
792
(144*5.5)
864 (144*6)
Running Efficiency ()
(%)
93.29% 92.51% 91.75% 91.00% 90.26%
Operator workload(%) 70.85% 81.66% 90.03% 98.41% 106.79%
0.00%
20.00%
40.00%
60.00%
80.00%
100.00%
120.00%
E
f
f
i
c
i
e
n
c
y
(
%
)
TFO-PRN
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 3
Designation Proposed Manpower - - - 3
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 1 15.00 15.00
2 1 1 12.67 12.67
3
1 3.56 3.56
4 1 1 5.00 5.00
5
1
1020
cones
122.40 122.40
6
1
306
faulty
cones
70.38 70.38
7
1
510
cones
30.60 30.60
A 259.61
B 14
C 295.96
D 450
E 65.77%
F 3
G 65.77%
PACKING
CHECKER
Activity Description
Confirm lot and count detail in sample register before
checking
Alloted lot sticker ready by SAP before checking
Checking individual cones and putting sticker
In case of a faulty cone - checking time
Paste a sample of new lot in sample register with
Final lot cone check in all packing dept. and do
separately
Take charge of packing area
WLS No: ESP/W/34
WORK LOAD DETAILS SHEET
BTM
Shifts A B C G
PACKING
Basic Workload per Shift ( in man minutes)
Remarks:
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 2
Designation Proposed Manpower - - - 1
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
1 114 1.57 178.60
2
1 114 0.82 93.10
3 1 114 1.00 114.00
4
1 1 15.00 15.00
A 400.70
B 13
C 452.79
D 480
E 47.17%
F 1
G 94.33% Proposed Utilisation(%)
Present Utilisation(%)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Lot final Checker
B C
Write the details on the log book like b.no,shade color
etc
Remarks:
Adjust the trolley weight & number of cones by
weighing
At the day end ,cross check & verify the quantity packed
and despatched
Proposed Manpower per shift
Basic Workload per Shift ( in man minutes)
Write the details on the bag using marker
Net Available man-mins
WLS No: BSP/W/35
WORK LOAD DETAILS SHEET
BTM Spinning
Shifts A G
Packing
Activity Description
Packing Room
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 6
Designation Proposed Manpower - - - 5
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
1 5344 0.07 356.27
2
1 167 0.13 21.43
3
1 167 0.83 139.17
4
1 167 0.13 21.43
5 1 167 1.57 261.63
6
1 167 0.07 11.13
7
1 167 0.53 87.68
8 2 167 1.43 478.73
9 1 167 0.30 50.10
10 1 167 0.82 136.94
11
1 167 0.47 77.93
12
1 167 1.10 183.70
A 1826.15
B 14
C 2081.81
D 480
E 72.28%
F 5
G 86.74%
Remarks:
No of cones / bag - 32 nos of 2kg each
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Based on machine capacity number of bags to be packed - 167 bags
Take the covered cones from ground and keep on the
trolley
Adjust the cones for exact weight in the weighing
machine
Take the white bag from area and spread it on the
box
Stitch the bags
Prepare the needle
Basic Workload per Shift ( in man minutes)
Prepare the rope(take and extend)
Tie the bag with rope and keep aside
G
Move trolley from weighing machine to bag area
Put the cones from trolley into white bags
Packing Room
Packing Helpers
Activity Description
Put the individual cones in the LDPE bag
Move the empty trolley from weighing machine to
cone storage area
Packing
Move the trolley back to weighing machine
After discussion, it is found that the one kg cone packing is rare,hence not considered.
WLS No: BSP/W/36
WORK LOAD DETAILS SHEET
BTM Spinning
Shifts A B C
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre
Present
Manpower
3 2 - 1 6
Designation
Proposed
Manpower
3 2 - 1 6
Sl.
No
Crew
Size
Freq/
Shift
Sample
Size
Basic
Time
(Mins)
Total
Time
(Mins)
1
1 6 lots
2
samples/f
ibre
15.57 15.57
2
1 4 shades
2
readings/
fibre
190.60 190.60
3
1 2 shades
2
readings/
fibre
40.67 81.34
4
1 1 lot
20
readings/
Lot
58.44 58.44
5
1 4 drums
6
readings/
drum
31.46 31.46
6
1 4 lots
20
readings/
Lot
29.47 29.47
7
1 1 bag 32 cones 33.60 33.60
8
1
All tested
lots
5.58 5.58
9
1 22 m/c
2gm/sam
ple & 4
samples/
day
31.94 31.94
11
1 4m/c
2
sample/m
/c
12
1 4 m/c
5
readings/
m/c
44.13
Card sliver wrapping check, report
preparation & disposal of samples
Sampling of card sliver samples for wrap
checking
44.13
Lab
Checker&
Investigator
Activity Description
Sampling of fibre samples from fibre
dyeing deptt. & fibre godown.
Autoconer single yarn splice app. &
strength checking(All single pack lots),
collection of spliced yarn samples, pasting
them in the register, report preparation.
Autoconer single yarn splice app. &
strength checking(Drumwise), collection of
spliced yarn samples, pasting them in the
register, report preparation.
Fibre moisture content% checking-
Polyester & Viscose & disposal of
samples.
Fibre neps/gm checking- Viscose &
disposal of samples.
WLS No: BSP/W/37
WORK LOAD DETAILS SHEET
QA-BTM
Shifts A B Total
QA
C G
Entry of all tested results of Splice & TPI
in lot history & information to all
concerned persons
Sampling of card sliver samples for neps
checking
Final Yarn TPI & TPI CV% checking(All
single pack & double pack)
Final Yarn case checking-weighment of
individual cones & yarn defects
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre
Present
Manpower
3 2 - 1 6
Designation
Proposed
Manpower
3 2 - 1 6
Sl.
No
Crew
Size
Freq/
Shift
Sample
Size
Basic
Time
(Mins)
Total
Time
(Mins)
Lab
Checker&
Investigator
Activity Description
WLS No: BSP/W/37
WORK LOAD DETAILS SHEET
QA-BTM
Shifts A B Total
QA
C G
13
1 2 m/c
2
samples/
m/c
14
1 2 m/c
5
readings/
m/c
15
1
1 m/c
delivery
5
cans/m/c
16
1 1 m/c
20
readings/
m/c
delivery
17
1 5 m/c
5
bobbins/
m/c
18 1 5 m/c 5 m/c
19
1 1 m/c
10
bobbins/
m/c
20
1 1 m/c 1 m/c
21
1
7 lots(2
times/we
ek)
4
samples/
lot
22
1 1/6
5 m/c in
one day
23 1 7 m/c 7 m/c 15.03 15.03
24
1 1 lot
10
coness/lo
t
4.45 4.45
25
1 4 lots
6
cones/lot
26
1 1 lot
10
cones/lot
23.84 23.84
Sampling of final yarn(double) cones for
yarn uster %, wrapping & TPI testing
Sampling of roving bobbins for wrapping
& CV% check
12.35 12.35
Simplex roving wrapping CV% check,
report preparation & disposal of samples
Sample preparation of roving for half lea
strength testing & carry them to BTM spg.
QA 10.76 10.76
Simplex roving half lea strength checking
at BTM spg. QA & report preparation
7.56 7.56
Drawframe sliver wrapping checking,
report preparation & Disposal of samples
Sampling of Roving bobbins for wrapping
check
33.35 33.35
Simplex roving wrapping check, report
Sampling of drawframe sliver(finisher)
samples for wrapping & CV% checking
10.26 10.26
Drawframe sliver wrapping checking,
report preparation & Disposal of samples
Sampling of drawframe sliver(finisher)
samples for wrapping & CV% checking
Autoconer Yarn cuts per 100 km checking
Sampling of autoconer yarn cones for
wrapping checking
Sampling of final yarn(single) cones for
yarn uster %, wrapping & TPI testing
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre
Present
Manpower
3 2 - 1 6
Designation
Proposed
Manpower
3 2 - 1 6
Sl.
No
Crew
Size
Freq/
Shift
Sample
Size
Basic
Time
(Mins)
Total
Time
(Mins)
Lab
Checker&
Investigator
Activity Description
WLS No: BSP/W/37
WORK LOAD DETAILS SHEET
QA-BTM
Shifts A B Total
QA
C G
27
1
All tested
lots
19.19 19.19
28
1
52
samples
5
bobbins/s
ample
29
1 26 m/c
52
samples
30
1 4 lots
10
bobbins/l
ot
31
1 4 lots
20
readings/
lot
32
1 4 lots
3
samples/l
ot
33
1 4 lots
3
samples/l
ot
34
1 1 lot
20
readings/l
ot
18.56 18.56
35
1 3 lots
20
readings/l
ot
55.68 55.68
36
1
All tested
lots
12.34 12.34
37
1 4 lots
10
bobbins/l
ot
Sampling of Ringframe yarn bobbins for
RKM testing & carry them to BTM spg.
QA
155.70 155.70
Final autoconer yarn wrapping check(all
single pack lots) & CV% , report
preparation & disposal of samples.
77.50
Ringframe yarn wrapping check, report
preparation & disposal of samples.
Ringframe yarn sampling of all new lots.
42.45
Ringframe yarn samples collection for
checking of blend%, washing fastness
&MFS checking at Lab
77.50
Entry of all card neps, card, drawframe,
simplex wrapping, autoconer yarn cuts in
lot history & information to all concerned
persons
Ringframe Yarn sampling(All m/c & all
sides)
42.45 Sending & submitting the yarn samples to
process lab for blend% , washing fastness
& MFS checking & updating the results in
lot history register
Ringframe yarn wrapping & wpg. CV%
checking(All new lots), report preparation
& disposal of samples
Final double yarn wrapping & CV%
check, report preparation & disposal of
samples.
Entry of ringframe & final yarn wrapping,
yarn blend%, washing fastness, MFS in lot
history & information to all concerned.
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre
Present
Manpower
3 2 - 1 6
Designation
Proposed
Manpower
3 2 - 1 6
Sl.
No
Crew
Size
Freq/
Shift
Sample
Size
Basic
Time
(Mins)
Total
Time
(Mins)
Lab
Checker&
Investigator
Activity Description
WLS No: BSP/W/37
WORK LOAD DETAILS SHEET
QA-BTM
Shifts A B Total
QA
C G
38
1 4 lots
30
readings/l
ot
39
1 4 lots
10
bobbins/l
ot
40
1 4 lots
30
readings/l
ot
41
1 4 lots
5
cones/lot
42
1 4 lots 10 kg/lot
43
1
All tested
lots
44
1 4 lots
6
cones/lot
45
1 4 lots
150
km/lot
46
1
All tested
lots
47
1 4 lots
6
cones/lot
48
1 4 lots
150
km/lot
Sampling of autoconer yarn cones for yarn
classifault testing & carrying them to BTM
classifault testing room
187.50 187.50
Autoconer yarn classifault testing, yarn
faults collection, pasting them in report,
report preparation & disposal of samples.
Sampling of final yarn cones for yarn
rewinding study
331.12 331.12
Final yarn rewinding study-checking on
m/c , yarn faults collection, pasting of yarn
faults in report, report preparation &
disposal of samples.
Entry of Ringframe yarn RKM, final yarn
RKM & rewinding studies in lot history &
information to all concerned persons.
Sampling of final yarn cones for yarn
classifault testing & carrying them to BTM
Classifault testing room.
96.00 96.00
Final yarn classifault testing-checking on
m/c, yarn faults collection, pasting of
gaults & report preparation & disposal of
samples.
Entry of final yarn classifault test results in
lot history & information to concerned
persons.
155.70 155.70
Ringframe yarn RKM & RKM CV%
checking, report & disposal of samples
Sampling of final yarn cones for RKM
testing & carry them to BTM spg. QA
Final Yarn RKM & RKM CV% checking,
report & disposal of samples.
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre
Present
Manpower
3 2 - 1 6
Designation
Proposed
Manpower
3 2 - 1 6
Sl.
No
Crew
Size
Freq/
Shift
Sample
Size
Basic
Time
(Mins)
Total
Time
(Mins)
Lab
Checker&
Investigator
Activity Description
WLS No: BSP/W/37
WORK LOAD DETAILS SHEET
QA-BTM
Shifts A B Total
QA
C G
49
1
All tested
lots
50
1 1/13
3 m/c in
one
round
51
1 1/13
3 m/c in
one
round
52
1 1/13
6
samples/
m/c
53
1 1/13
2 m/c in
one
round
54 1 1/26 All m/c 1.44 1.44
55
1 1/26
2 m/c in
one
round
4.04 4.04
56
1 1/26
26 m/c in
one
round
3.46 3.46
57
1 1/26
26 m/c in
one
round
9.23 9.23
58
1 1/26
26 m/c in
one
round
6.92 6.92
59
1 1/13
8m/c in
one
round
18.46 18.46
60
1 1/26
2 m/c in
one
round
9.23 9.23
17.31
Autoleveller function checking-
wrapping,wpg. CV% & A%, report
preparation & disposal of samples.
Ring frame suction pressure checking &
report preparation
Ringframe cots checking & report
preparation
Ringframe spacer checking & report
preparation
Autoconer gauge setting checking & report
preparation.
Cheese winding yarn tension checking &
report preparation.
M/c speed checking & report preparation
Simplex Top arm pressure & report
preparation
187.50
Sample preparation of Autoleveler function
checking
17.31
187.50
Entry of autoconer yarn classifault test
results in lot history & information to all
concerned persons.
Blow room lap weight checking, report
preparation
8.46 8.46
Blow room lap CV% check, report
preparation & disposal of samples
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre
Present
Manpower
3 2 - 1 6
Designation
Proposed
Manpower
3 2 - 1 6
Sl.
No
Crew
Size
Freq/
Shift
Sample
Size
Basic
Time
(Mins)
Total
Time
(Mins)
Lab
Checker&
Investigator
Activity Description
WLS No: BSP/W/37
WORK LOAD DETAILS SHEET
QA-BTM
Shifts A B Total
QA
C G
61
1 1/26
2 m/c in
one
round
2.31 2.31
62
1 1/26
4 m/c in
one
round
2.31 2.31
63
1 1/26
24 in one
round
12.69 12.69
64
1 1/26
8
samples/s
tudy
65
1 1/26
24
samples/s
tudy
66
1 1/26
8
samples/s
tudy
91.90 91.90
1
1 1 1 7.45 7.45
2
1 1 1 5.00 5.00
3
1 1 0.85 0.85
1 1 0.95 0.95
1 1 1.06 1.06
1 2 2.17 4.34
1 1 0.90 0.90
4
1 1 0.30 0.30
1 3 0.54 1.62
1 3 0.30 0.90
1 3 0.33 0.99
Enter details in the UT
Uster % checking & print the result
Keep back the cans in carding section
Collect the sample can and come back to
QA
Enter the details in the UT machine
Cheese winding breakage study & report
preparation.
Carding
Reach carding section from QA
TFO breakage study & report preparation.
Knotter's knot quality checking, pasting
them in report & report preparation.
Samples preparation for Cardwise sample
study on same machine channel for each
individual card.
Cardwise study- classimat tests of RF yarn
samples (Testing at Classimate room at
BTM spg.) & disposal of samples.
Investigator
Clean the uster machine, work area , go
and bring mixing register
Enter the mixing composition and other
details in lot register from layering register
137.85 137.85
Cardwise sample study- Uster checking of
card sliver, Drawframe sliver & Ringframe
yarn
Drawframe(Breaker &Finisher)
Come to drawframe section, collect two
can(breaker)
Come back to QA lab
Write on the can L/L,L/R
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre
Present
Manpower
3 2 - 1 6
Designation
Proposed
Manpower
3 2 - 1 6
Sl.
No
Crew
Size
Freq/
Shift
Sample
Size
Basic
Time
(Mins)
Total
Time
(Mins)
Lab
Checker&
Investigator
Activity Description
WLS No: BSP/W/37
WORK LOAD DETAILS SHEET
QA-BTM
Shifts A B Total
QA
C G
1 12 1.77 21.24
1 3 0.54 1.62
1 1 0.46 0.46
1 3 0.54 1.62
1 3 0.33 0.99
1 12 1.77 21.24
1 3 0.54 1.62
5
0.00
1 9 0.54 4.86
1 9 0.15 1.35
1 9 1.51 13.59
1 36 1.47 52.92
6
1 1 1.53 1.53
1 8
8 lot*10
reading/l
ot
1.13 9.04
1 1 0.67 0.67
1 8 1.22 9.76
1 8 14.10 112.80
1 8 0.50 4.00
1 1 5.00 5.00
7
1 8 0.35 2.80
1 8 0.26 2.08
Uster % checking & print the result(2 pass
per can*2 cans/machine*3 machine)
Move the simplex trolley to QA lab
Enter the details in the UT machine
Keep back the cans in the breaker section
Waiting for the cans (finisher)
Uster % checking & take the printout(4
readings/machine*9 machine)
Ringframe
Come to ringframe section, searching for
the product running machine
Collect the R/F bobbins(10
bobbins/machine*8 machine)
Collect two cans, Come to QA lab
Enter details in the UT
Uster % checking & print the result(2 pass
per can*2 cans/machine*3 machine)
Keep back the cans in the finisher area
Simplex Machine
Come to simplex area from QA lab
Come back to QA lab
Enter the parameters in uster machine
Check the uster % ( 10 bobbins)(operator
workload)
Take the printout of the result
During the uster % machine cycle time
filled the yesterday report in the log book
Yarn Board Winder
Take the white board and fix on the
machine
Fix the yarn from bobbin to board and
switch on
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre
Present
Manpower
3 2 - 1 6
Designation
Proposed
Manpower
3 2 - 1 6
Sl.
No
Crew
Size
Freq/
Shift
Sample
Size
Basic
Time
(Mins)
Total
Time
(Mins)
Lab
Checker&
Investigator
Activity Description
WLS No: BSP/W/37
WORK LOAD DETAILS SHEET
QA-BTM
Shifts A B Total
QA
C G
1 8 0.39 3.12
1 8 0.80 6.40
8
0.00
1 2 1.04 2.08
1 20 0.15 3.00
1 20 1.00 20.00
0.00
9
1 6
6 lot*10
reading/l
ot
0.35 2.10
1 6 0.26 1.56
1 6 0.39 2.34
1 6 0.80 4.80
10
1 1 4.00 4.00
11
1 1 8.00 8.00
12
1 1 3.00 3.00
13
1 1 10.00 10.00
14
Take the white board and fix on the
machine
Single Yarn Uster% checking(materials
already brought to QA by checker)
Enter details in the UT machine
Fix date slip, remove the YBW board and
keep near the UT machine
Write details in the small slip to insert in
the YBW board
Enter the uster test results in lot history
register & file all reports
Remove the old and Connect the next
single yarn cone to the UT machine
Machine cycle time(2 lot*10 readings/lot)
During the machine cycle time,parallely
keep the old cones in the trolley)
Yarn Board Winder(Final Yarn)
Fix the yarn from cone to board and switch
on
Fix date slip, remove the YBW board and
keep near the UT machine
Write details in the small slip to insert in
the YBW board
Fill the D/F uster & spectrogram report
from quality report
Enter the daily production lot register data
in excel sheet
Send the daily QA report through mail to
higher officials
Sampling of Packing materials
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre
Present
Manpower
3 2 - 1 6
Designation
Proposed
Manpower
3 2 - 1 6
Sl.
No
Crew
Size
Freq/
Shift
Sample
Size
Basic
Time
(Mins)
Total
Time
(Mins)
Lab
Checker&
Investigator
Activity Description
WLS No: BSP/W/37
WORK LOAD DETAILS SHEET
QA-BTM
Shifts A B Total
QA
C G
1 1/13 120.00 9.23
1 1/13 120.00 9.23
1 1/13 60.00 4.62
1 1/13 60.00 4.62
A 2353.02
B 13
C 2658.92
D 2730
E 97.40%
F 6
G 97.40%
Present Utilisation(%)
Proposed Manpower per Day
Proposed Utilisation(%)
Remarks:
Basic Workload per shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Standard Workload ( in man minutes )
Net Available man-mins
Sample the paper cone(embossed),Check
the weight,strength,Cone length, nose dia,
base dia (20 cone for 50,000 lot)
Sample the HM bag, Test
length,weight,gauge (10 readings for 150
kg)
Sample the HDPE bag, Test
length,weight,gauge (10 readings for 300
kg)
Sample the paper cone(plain velvet),Check
the weight,strength,Cone length, nose dia,
base dia (20 cone for 50,000 lot)
________________________________________________________________________________________
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________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
4.0 A BTM SPINNING - MECHANICAL
MAINTENANCE
_______________________________________________________________________________
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
4.0 A
4.1
I II III G T I II III G T
Fitter - - - 1 1 - - - 1 1
Helper - - - 2 2 - - - 1 1
Fitter - - - 1 1 - - - 1 1
Running Fitter - - - 1 1 - - - 1 1
Cleaner - - - 2 2
Flat Grinder - - - 1 1
Fitter - - - 1 1 - - -
Running Fitter - - - 1 1 - - -
Cleaner - - - 3 3 - - - 3 3
Fitter - - - 1 1
Helper - - - 1 1
Head Fitter - - - 1 1 - - - 1 1
Gauging Ftter - - - 1 1 - - - 1 1
Helper - - - 2 2 - - - 2 2
Duct Fitter - - - 1 1 - - - 1 1
Cleaner - - - 8 8 - - - 8 8
Cleaner Fitter - - - 1 1 - - - 1 1
Asst. Cleaner Fitter - - - 1 1 - - - 1 1
- 2
-
1
2
Common Cleaning
gang for Ringframe &
TFO
Ringframe 5
Main Gang
1 - -
1
Blow Room
1
- -
1
Carding 2
Fly-Frame 3
4 Buffing
BTM SPINNING - MECHANICAL MAINTENANCE
Manpower Deployment
S. No Section / Work area Designation
Present Manpower Proposed Manpower
Remarks
_________________________________________________________________________________________________________________________
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4.0 A
4.1
I II III G T I II III G T
BTM SPINNING - MECHANICAL MAINTENANCE
Manpower Deployment
S. No Section / Work area Designation
Present Manpower Proposed Manpower
Remarks
Fitter - - - 2 2 - - - 2 2
OHB Fitter - - - 1 1 - - - 0 0
Cleaner - - - 3 3 - - - 3 3
Fitter - - - 1 1 - - - 1 1
Helper - - - 1 1 - - - 1 1
0 0 0 38 38 0 0 0 33 33 Total
Winding 6
TFO 7
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________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
4.0 A
4.2
4.2.1
a)
b)
c)
d)
e)
f)
-
-
-
-
-
-
-
-
-
-
g)
BTM SPINNING - MECHANICAL MAINTENANCE
Proposed Changes & Observations
Running maintenance data has been collected by detailed discussions with the
incumbents and the supervisory personnel and compared with check studies and
estimated.
The manpower has been computed with a loading factor of 80 % for the maintenance
personnel. The 80 % loading has been considered to take into account the following:
The detailed time and motion study is recommended to arrive the standard time for the
activities,whatever timings considered here,based on the group utilisation technique.And
cannot taken for fixing standard times.
The preventive maintenance data was collected for all the category of machines.
Check studies on a sample basis were carried out to ascertain the process being
followed for the preventive maintenance. The data gathered during check studies has
been applied to the remaining preventive maintenance activities in that section.
Methodology
Breakdown maintenance (Carding, Ringframe & Autowinding) data has been
obtained for a period of two months and the same has been extrapolated for a month.
The sum of the preventive maintenance, breakdown maintenance(if any) and running
maintenance (if any) workload for the month gives us the total workload for the
mechanical personnel.
Rest & Relaxation allowance is already included as a part of activity time and
presented against the respective activities.
PF - Permanent Fitter(Sr.Fitter,Fitter,Jr.Fitter)
PH - Permanenent Helper/Cleaner
Waiting for the machine for maintenance
Clean the tool room daily morning
Bring tools/materials from store Ex: oil,grease,waste cloth, new parts
Discard the waste cloth to the waste area daily after maintenance work
Change dress
Prepare attendance
Write logbook
Unavoidable delay. EX:New activity cannot start after 4.30 pm as only 30 mins left
for that day
Arranging of tools & parts in tool room
Efforts variation required
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________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
4.0 A
4.2
BTM SPINNING - MECHANICAL MAINTENANCE
Proposed Changes & Observations
4.2.2
I
a)
II
a)
b)
III
a)
IV
a)
V
a)
Proposed Changes
Blowroom
In view of low utilisation(29.68%) of helpers in the blowroom section, it is proposed
to deploy one helpers instead of the present two helper with one fitter.
Cots Buffing
Drawframe & Simplex(Fly-Frame)
BTM-D/F & Simplex section, one separate fitter deployed for running problems &
change over activities. It is suggested to follow the same practice of all
members(fitter, cleaners) perform the routine checkups (for their sections) at the
starting of the shift and rectify(if problem any) the same before starting the scheduled
preventive maintenance activity. Incase of small running problems, the fitter can
attend the problem. This will not affect the scheduled maintenance activities as the
fitter involvement is less. In above that they have foreman to carryout the running
problems & breakdowns. This practice is already implemented in elegant spinning.
In view of low utilisation(19.69%) , it is proposed to deploy one fitter instead of the
present one fitter and one helper.
OHB Fitter
The incumbent is incharge for the OHB in the BTM Spinning section. The major
activity is collecting the dust accumulated from the OHB box & do overhauling of
the OHB. As single operator walking to all the OHB and collecting waste, it takes
nearly 3 hours per day. So, it is recommended that the respective section mechanical
gang carryout the maintenance of their sections OHB. This practice is being followed
in Elegant Spinning. No separate personnel is being recommended for this position.
After the detailed discussion with the mechanical team and the management
personnel, the number of running problems through out the day are very minimal
compared to in elegant spinning. Hence, no personnel is deployed in shift for
attending the minor/running problems. The same is being considered and manpower
is suggested.
Carding-Flat Grinder
The utilisation of flat grinder is only 12.5%. So it is recommended that one flat
grinder cum cleaner, instead of flat grinder.
_______________________________________________________________________________
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________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
4.0 A
4.2
BTM SPINNING - MECHANICAL MAINTENANCE
Proposed Changes & Observations
4.2.3
I
a)
b)
II
a)
III
a)
Multiple Activity Chart:
Multiple activity chart is used when more than one personnel is engaged for doing
one job. A multiple activity chart combined with SOP gives the sequence of activity
each has to perform. This reduces the idle time and increases the machine availability
time. It was observed during the study that such detailed Multiple Activity Chart
combined with SOP is not available as a result of which the time taken for scheduled
maintenance is much higher than required. Hence it is proposed that a detailed time and
motion study for regular maintenance activities has to be carried out and such Multiple
Activity Chart has to be made.
Instead of stopping machine two different times, the activity of cleaning gangs(S.No
1-6) could be performed, when machine stopped by gauging gang to carryout their
scheduled activities. As gauging gang working on gear part (removed geared from
machine and overhauling in the mechanical room), remaining part of the machine is
free for cleaning. It increases the machine availability to the production. Illustration
is provided in Annex-1
Ringframe - Oil Top up activity
The activity of oil topping is performed by eight personnel for their allotted spindle ( 55
Spindles per person). As there is presently only one can is available, all seven are idle
while one person fills his allotted spindles and made machines to be stopped. The time
taken for oil topping could reduce drastically. Illustration is provided in Annex-2
Ringframe & TFO
There are two different gangs performing scheduled maintenance activity in
Ringframe section Called as Cleaning gang and Gauging Gang. Cleaning gang
performs activities from S.No 1 6 and Gauging gang performs activities from S.No
8 16.(in the monthly Schedule For Routine/ Preventive Maintenance List)
During the study and discussion, it is observed that machine is being stopped
separately by cleaning gang and separately by gauging gang to perform their
respective scheduled maintenance activities.
Observations
_______________________________________________________________________________
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________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
4.0 A
4.2
BTM SPINNING - MECHANICAL MAINTENANCE
Proposed Changes & Observations
4.2.3
IV
a)
b)
V
a)
VI
a)
Observations
Break-hours
It is observed that in elegant spinning that mechanical workers first finishes their
activities and leaving for breaks , because of this the machine hours under
maintenance decreases. Whereas in BTM this good practice is not observed results
in the reduced hour machine availability for the production.
Total Time provided for Scheduled Maintenance
The time provided for scheduled maintenance activities are based on the company
experience/estimation. However, it was observed during the study that the actual time
required for the scheduled maintenance activities are less. So , it is recommended to
go for in-depth time and motion study and fix standards for the regular maintenance
activities. This will help in increasing the availability time of machine and also
reduce maintenance personnel workload further.
In Spinning mill, number of similar equipments are more ( 48 R/F,48 TFO) , and
activity also carried out once in a month/quarter, reduction of each minutes have big
impact in the machine availability to production. Illustration is provided in Annex-3
Pooling of Workforce
It is observed in BTM-TFO mechanical gang (1 Fitter+1 Helper) performs the
preventive maintenance activities. For example, thread guide setting and cradle drum
setting which takes 2.17 hours with two crew personnel. The same activity if carried
out by say four personnel, the machine down time for maintenance would be half of
the time taken(2.17/2 = 1.09 hours). In the same day, morning in cheese winding
section, with 3 helpers+1 fitter carried out machine cleaning activity. For that they
stopped cheese winding machine for 3 hours. By pooling this two group ( TFO-2
Personnel + Cheese winding - 4 personnel) , both the activity would have been
completed, but with the half of the both machine stopped presently. This type of
analysis is possible only when the multiple activity chart with activity
sequence(preceding/succeeding) of activity known.
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Annex : 1
Section : BTM - Spinning - Ring Frame
RING FRAME
S.NO. ACTIVITY Frequency
Approx
Time
(hrs)*
Done
by
1 M/C Cleaning 15D +_15D 1.25 1.25 1.25
2 Spindle Oil 4 M + 15 D
Topping
3 Spdl.Oil Change 1 Y + 2 M 0.5 0.5 0.5
4 Bottom Apron 8 M + 2 M
Change
6 Middle Arbour 1 Y + 2 M 0.5 0.5
Greasing
7 Draft Gear 6 M + 1 M
Overhauling
8 Heart Cam As & when
Overhauling required
9 J.P.Ball Brg. 1 Y + 2 M
Greasing
10 Bottom Roll 1 Y + 2 M
Trueing
11 Lapet Hook 2 Y + 3 M
Change
12 Lifting OH 2 Y + 6 M 12
13 Spindle Gauge 8 M + 1 M 4 Requirement Prior scheduling
14 Rings Change 2 Y + 6 M
This practise is being follwoed in Elegant mechanical maintenance
15 Spindle Change 10 Y + 2 Y 12
Present Method Proposed Method
0.5
P
e
r
f
o
r
m
e
d

b
y

C
l
e
a
n
i
n
g

G
a
n
g
0.5 0.5
12
Same improvement idea holds good in TFO Section, where two gangs are involved.
Performed by Gauging gang
Performed by Cleaning gang
4
P
e
r
f
o
r
m
e
d

b
y

G
a
u
g
i
n
g

G
a
n
g
4
12
4
4
0.5 0.5
0.5
0.5
Savings per machine - 3.25
hours
2
4
Total Machine Stoppage -
1.25+0.5+0.5+0.5+0.5 + 4 = 7.25
hours
Total Machine Stoppage - 4
hours
__________________________________________________________________________________________________________________________________________________________
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Annex : 2
Section : BTM - Spinning - Ring Frame
Activity : Spindle oil Topping
24 24
21 21
18 18
15 15
12 12
9 9
6 6
3 3
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
Working ( Remove spindle, fill the oil & place back the spindle)*
Idle
Additionally cleaners avaialblity goes up
Waiting for the Oil can ( Forced Idleness)
Time saved per machine - 18 mins
Present Method ( with One oil Can) Proposed Method ( with four oil can)
T
i
m
e

(

m
i
n
s
)
T
i
m
e

(

m
i
n
s
)
Crew Size ( Cleaners) Crew Size ( Cleaners)
Total Cycle time per machine = 24 mins Total Cycle time per machine = 6 mins
_________________________________________________________________________________________________________________________
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______________________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Annex : 3
Section : BTM - Spinning - TFO
T.F.O.
S.NO. ACTIVITY Frequency
Appro
x
Time
Done By
11
Thread guide Setting
6 M + 1 M
12 6 M + 1 M
13 Jokey Pulley Greasing 1 Y + 2 M 2.5 Total Machine Stoppage - 3 Hours
14 1 Y + 2 M
Total Crew(6 person) Utilisation - 1 hour
CONE WINDING & CHEESE WINDING
S.NO. ACTIVITY Frequency
Appro
x
Done By
1
M/C Cleaning with
Upper & 15 D + 4 D
Lower Guide pulley
Oiling
2 Drum shaft brg.&greasing 6 M + 1 M 8 Total Machine Stoppage - 3 Hours
3 Yarn Path 3 M + 15 D
Setting
6 Yarn guide hook As & when
required
GBTL -SPG-F-08 TFO Autoconer TFO Autoconer TFO Autoconer
* Given by company persons
Machine
Stoppag
e Hours
3 3
Machine
Stoppage
Hours
1 2
Machine
Availablity
for
production
(extra)
2 1
Manhour
s
Utilised
2 crew*
3
hours=
6
manhou
rs
4 crew*3
hours=12
manhours
Manhours
Utilised
6 crew* 1
hours= 6
manhours
6 crew*2
hours=12
manhour
s
- -
3
P
e
r
f
o
r
m
e
d

b
y

T
F
O

G
a
u
g
i
n
g

G
a
n
g



(

1

F
i
t
t
e
r
+

1

H
e
l
p
e
r
)
Total Crew(4 person) Utilisation
- 3 hours
Present Method Proposed Method
Total Crew(2 person) Utilisation
- 3 hours
Cradle, Drum Setting
Gear Overhauling
3

P
e
r
f
o
r
m
e
d

b
y

A
u
t
o
c
o
n
e
r

C
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e
a
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i
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G
a
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(

Autoconer Gang( 1 Fitter + 3
Helpers)
Total Crew(6 person) Utilisation - 2 hours
4
4
4
Total Autoconer Machine Stoppage - 2 Hours
Proposed Method ( 2TFO Gang
+ 4 Autoconer Gang)
Present Method
Savings
6 Persons( 2 TFO
Gang + 4 Autoconer
Gang)
TFO Gang ( 1 Fitter + 1 Helper)
6 Persons(
2 TFO Gang
+ 4
Autoconer
Gang)
Total TFO Machine Stoppage - 1 Hours
__________________________________________________________________________________________________________________________________________________________
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________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
4.0 A
4.3
S.No
1
2
3
4
5
6
7
8
9
10
11
12
OHTC Fitter BSM/W/11
TFO BSM/W/12
Ring frame-Main Gang BSM/W/08
Duct Fitter BSM/W/09
Autowinding&Cheese Winding BSM/W/10
Running Fitter- BSM/W/05
Cots Buffing BSM/W/06
Cleaning Gang-R/F&TFO BSM/W/07
Carding BSM/W/02
Flat Grinder BSM/W/03
Drawframe&Simplex BSM/W/04
BTM SPINNING - MECHANICAL MAINTENANCE
Workload Sheets Summary
Area of work WLS Number
Blow Room BSM/W/01
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 1 F+2 H
Work Centre
Blowroom &
Mixing
- - - 1 F+1 H
PF PH PF PH
A Blowroom & Mixing
1 Line Blender Cleaning 1 1 1 3.0876 5 15 15
a) Clear the material from the machine and
stop the machine
b) Dismantle the grid bar
c) Cleaning the grid bar
d) Mantling of the grid bar
e) Cleaning of the beater and striping plate
f) Cleaning of the feed lattice
g) Cleaning of the inclined lattice
h) Cleaning of the bottom inclined lattice
i) Cleaning of the evener roller/lattice
j) Cleaning of the feed roll
k) Checking and greasing of the bearings
l) Close the cover of the machine and start
the machine
WORK LOAD DETAILS SHEET
Time
(in Hours)
No of
Machine
Crew Category
WLS No:BSM/W/01
Present
Manpower
Proposed
Manpower
Shifts
S.
No
Activity Description
Frequency/
Month
Monthly
workload(Hours)
_________________________________________________________________________________________________________________________
National Productivity Council, Bangalore.
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 1 F+2 H
Work Centre
Blowroom &
Mixing
- - - 1 F+1 H
PF PH PF PH
WORK LOAD DETAILS SHEET
Time
(in Hours)
No of
Machine
Crew Category
WLS No:BSM/W/01
Present
Manpower
Proposed
Manpower
Shifts
S.
No
Activity Description
Frequency/
Month
Monthly
workload(Hours)
2 Hopper Feeder Cleaning 1 1 1 3.0876 5 15 15
a) Clear the material from the machine and
stop the machine
b) Removal of the chain and belt
c) Opening and cleaning of the vibrating
door of the hopper feeder
d) Cleaning of the inclined lattice
e) Dismantling of the gears
f) Cleaning & checking of the gears
g) Mantling of the gears
h) Cleaning of the stripper roll
i) Cleaning of the evener roller/lattice
l) Close the cover of the machine and start
the machine
3 Condenser & Doffing Section cleaning.
1 1 1 3.0876 5 15 15
_________________________________________________________________________________________________________________________
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 1 F+2 H
Work Centre
Blowroom &
Mixing
- - - 1 F+1 H
PF PH PF PH
WORK LOAD DETAILS SHEET
Time
(in Hours)
No of
Machine
Crew Category
WLS No:BSM/W/01
Present
Manpower
Proposed
Manpower
Shifts
S.
No
Activity Description
Frequency/
Month
Monthly
workload(Hours)
a) Clear the material from the machine and
stop the machine
b) Cleaning of the cage
c) Cleaning of the striping roll
d) Close the cover of the condenser
e) Dismantling of the solenoid valves
f) Cleaning and mantling of the solenoid
valves
g) Dismantling of the calendar roll gear
h) Checking and cleaning of the calendar roll
gears
i) Cleaning & checking of the doffing arm
spring and arm
j) Checking and cleaning of the tire coupling
_________________________________________________________________________________________________________________________
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 1 F+2 H
Work Centre
Blowroom &
Mixing
- - - 1 F+1 H
PF PH PF PH
WORK LOAD DETAILS SHEET
Time
(in Hours)
No of
Machine
Crew Category
WLS No:BSM/W/01
Present
Manpower
Proposed
Manpower
Shifts
S.
No
Activity Description
Frequency/
Month
Monthly
workload(Hours)
k) Close the cover of the machine and start
the machine
4 Scutcher Cleaning 1 1 1 3.0876 5 15 15
a) Clear the material from the machine and
stop the machine
b) Dismantling of the paddles
c) Cleaning of the paddles
d) Dismantling of the grid bar
e) Cleaning of the grid bars
f) Mantling of the grid bars
g) Mantling of the paddles
h) Gauging of the paddle gauge
i) Checking of the cone drum
j) Opening and Checking of the PIV gear
k) Checking of the calendar roll gear
l) Cleaning of the beater and striping plate
_________________________________________________________________________________________________________________________
National Productivity Council, Bangalore.
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 1 F+2 H
Work Centre
Blowroom &
Mixing
- - - 1 F+1 H
PF PH PF PH
WORK LOAD DETAILS SHEET
Time
(in Hours)
No of
Machine
Crew Category
WLS No:BSM/W/01
Present
Manpower
Proposed
Manpower
Shifts
S.
No
Activity Description
Frequency/
Month
Monthly
workload(Hours)
m) Gauge of the feed roll to beater and
striping plate to beater
j) Close the cover of the machine and start
the machine
5 Mixing Blender Cleaning ( Mixing
Blender -4 nos, viscose opener-1 No)
1 1 1 2.70165 5 14 14
a) Clear the material from the machine and
stop the machine
b) Cleaning of the bottom lattice
c) Cleaning of the feed lattice
d) Cleaning of the inclined lattice
e) Cleaning of the bottom inclined lattice
f) Cleaning of the evener roller/lattice
g) Cleaning of the feed roll
h) Checking and greasing of the bearings
_________________________________________________________________________________________________________________________
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 1 F+2 H
Work Centre
Blowroom &
Mixing
- - - 1 F+1 H
PF PH PF PH
WORK LOAD DETAILS SHEET
Time
(in Hours)
No of
Machine
Crew Category
WLS No:BSM/W/01
Present
Manpower
Proposed
Manpower
Shifts
S.
No
Activity Description
Frequency/
Month
Monthly
workload(Hours)
i) Close the cover of the machine and start
the machine
6 Mxg. Condenser Cleaning 1 1 1 1.5438 11 17 17
a) Clear the material from the machine and
stop the machine
b) Cleaning of the cage
c) Cleaning of the striping roll
d) Cleaning of the mouth piece
e) Close the cover of the condenser
7 Gear box Oil Change 1/6 1 1 0.7719 12 2 2
a) Stop the machine and open the oil box
b) Removal of the old oil from the oil box
c) Cleaning of the gears
d) Putting of the new oil in to the oil box
_________________________________________________________________________________________________________________________
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 1 F+2 H
Work Centre
Blowroom &
Mixing
- - - 1 F+1 H
PF PH PF PH
WORK LOAD DETAILS SHEET
Time
(in Hours)
No of
Machine
Crew Category
WLS No:BSM/W/01
Present
Manpower
Proposed
Manpower
Shifts
S.
No
Activity Description
Frequency/
Month
Monthly
workload(Hours)
8 K. Beater Legs Change ( Blow Room -
2 have one leg at Front & One leg at
back)
1/9 1 1 7.719 6 5 5
a) Clear the material from the machine and
stop the machine
b) Removal of the KB Belt
c) Dismantling of the beater legs
d) Marking of the holes in the new beater
e) Drilling the hole in the beater legs
f) Fitting the beater legs on the beater
g) Balancing of the beater
h) Gauge the beater to feed roll and striping
to beater
i) Close the cover of the machine and start
the machine
9 Filter Bags Washing 1/3 1 1 0.38 21 3 3
a) Opening of the filter bags
b) Washing of the filter bags
c) Tight the filter bags on its position after
Performed by Carpenter.
_________________________________________________________________________________________________________________________
National Productivity Council, Bangalore.
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 1 F+2 H
Work Centre
Blowroom &
Mixing
- - - 1 F+1 H
PF PH PF PH
WORK LOAD DETAILS SHEET
Time
(in Hours)
No of
Machine
Crew Category
WLS No:BSM/W/01
Present
Manpower
Proposed
Manpower
Shifts
S.
No
Activity Description
Frequency/
Month
Monthly
workload(Hours)
10
Running Problems(During General Shift) 26 1
1 1 26
A 127.60 101.60
B 166.4 166.4
C 76.68% 30.53%
D 1 1
E 76.68% 61.06%
Total Workload per month ( in man hours )
Net Available man-hours per month(8*26*80% = 166.4 hours)
Present Utilisation(%)
Proposed Manpower
Proposed Utilisation(%)
_________________________________________________________________________________________________________________________
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 1 F+3 H
Work Centre Carding - - -
1F+2H+1 Flat
Grinder
PF PH PF PH
1 Full setting 1 1 3 2.4 26 62 187
a) Allow to run out the machine
b) Stop the machine
c) Remove lap roll, lap stand, Feed plate feed
roll,Lickerin,Undercasing
d) Clean the machine through Air Pressure
e) Clean all the Parts
f) Remove jam from all the place
g) Clean all the gearing
d) Reset all the gauge
f) Fix all the open parts in machine
g) Start the machine at slow speed for checking of any
abnormal sound
h) Clean the machine once through Air pressure
i) Start the machine
j) Handover to production Deptt
Frequency/
Month
Crew
Category
WLS No:BSM/W/02
WORK LOAD DETAILS SHEET
Shifts
Present
Manpower
Proposed
Manpower
No of
Machine
Monthly
workload(Hours)
S.
No
Activity Description Time
(in
Hours)
_________________________________________________________________________________________________________________________
National Productivity Council, Bangalore.
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 1 F+3 H
Work Centre Carding - - -
1F+2H+1 Flat
Grinder
PF PH PF PH
Frequency/
Month
Crew
Category
WLS No:BSM/W/02
WORK LOAD DETAILS SHEET
Shifts
Present
Manpower
Proposed
Manpower
No of
Machine
Monthly
workload(Hours)
S.
No
Activity Description Time
(in
Hours)
Overhauling
Cylinder Wire Change
Doffer Wire Change
Flat Tops Change
St.Flats ( Doffer ) change
Combing Segment Change
a) Allow to run out the machine
b) Stop the machine
c) Open the cover and Belts & whole machine
d) Remove lap roll, lap stand, Feed plate feed
roll,Lickerin,Undercasing
e) Remove the flats & Flat bend
f) Remove the old wire from Cylinder
g) Remove the old wire from Doffer
h) Take bare Reading of Cylinder and Doffer
i) Open all the gears
j) Fix mounting machine on Cylinder
k) Mount The cylinder
l) Fix mounting Machine on Doffer
26
2
23.227 69.68 1 3 21.44 1/24
_________________________________________________________________________________________________________________________
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 1 F+3 H
Work Centre Carding - - -
1F+2H+1 Flat
Grinder
PF PH PF PH
Frequency/
Month
Crew
Category
WLS No:BSM/W/02
WORK LOAD DETAILS SHEET
Shifts
Present
Manpower
Proposed
Manpower
No of
Machine
Monthly
workload(Hours)
S.
No
Activity Description Time
(in
Hours)
m) Mount the doffer
n) light grinding on Cylinder and doffer
o) Put the new St doffer side and Combing Segment
p) Assemble whole the parts and fix on machine
q) Fix all the gears on machine
r) Put new stationary flats on machine
s) Reset all the gauge
t) Start the machine at slow speed for checking of
abnormal sound
u) Handover the machine to Production
3 Stationary Flats ( Licker-in ) change 1/9 1 2 2.144 26 6 12
a) Remove licker in
b) Open all the stationary flats
c) Remove old Stationary Flats
d) remove Top and bottom Plate licker in side
e) Put new flats
f) Fix on machine
g) Fit the licker in on machine
h) Reset the gauge
_________________________________________________________________________________________________________________________
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 1 F+3 H
Work Centre Carding - - -
1F+2H+1 Flat
Grinder
PF PH PF PH
Frequency/
Month
Crew
Category
WLS No:BSM/W/02
WORK LOAD DETAILS SHEET
Shifts
Present
Manpower
Proposed
Manpower
No of
Machine
Monthly
workload(Hours)
S.
No
Activity Description Time
(in
Hours)
4 Licker-in Wire Change 1/9 1 1 2.144 26 6 6
j) Open the licker in wire
k) Mount the wire on licker in
5 Cylender,Doffer Grinding(28 in the last one year) 2 1/3 1 2 2.144 1 5 10
a) Allow to run out the machine
b) Fix the grinder on doffer
c) Set the gauge for grinder
d) Run grinder without contact of doffer wire
e) Give the contact of grinder to doffer wire
f) Remove the grinder from doffer
g) Stop the machine
h) Open the top and bottom plate and doffer side st flats
i) Reverse the direction of Cylinder
j) Put grinder on cylinder
k) Give the contact of grinder to cylinder
l) Stop the machine
m) Fix all the parts on machine
n) Reset the gauge
o) Start the machine
_________________________________________________________________________________________________________________________
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 1 F+3 H
Work Centre Carding - - -
1F+2H+1 Flat
Grinder
PF PH PF PH
Frequency/
Month
Crew
Category
WLS No:BSM/W/02
WORK LOAD DETAILS SHEET
Shifts
Present
Manpower
Proposed
Manpower
No of
Machine
Monthly
workload(Hours)
S.
No
Activity Description Time
(in
Hours)
6 Sharprite 1/6 1 2 2.144 26 9 19
a) Allow to run out the machine
b) Fix the grinder on doffer
c) Set the gauge for sharpener
d) Give the contact of sharpener to doffer wire
e) Remove the sharpener from doffer
f) Stop the machine
g) Open the top and bottom plate and doffer side st flats
h) Reverse the direction of Cylinder
i) Put sharpener on cylinder
j) Give the contact of sharpener to cylinder
k) Stop the machine
l) Fix all the parts on machine
m) Reset the gauge
n) Start the machine
_________________________________________________________________________________________________________________________
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 1 F+3 H
Work Centre Carding - - -
1F+2H+1 Flat
Grinder
PF PH PF PH
Frequency/
Month
Crew
Category
WLS No:BSM/W/02
WORK LOAD DETAILS SHEET
Shifts
Present
Manpower
Proposed
Manpower
No of
Machine
Monthly
workload(Hours)
S.
No
Activity Description Time
(in
Hours)
7 Clearer roller clothing change (7 in the last one year)
3/5 1 3 1.072 1 1 2
a) Allow to run out the machine
b) Stop the machine
c) Remove the clearer roll
d) Open the clothing
e) Mount the new clothing
f) Fix on machine
g) Reset the gauge
h) Start the machine
8 Gearbox oil change 1/8 1 1 1 26 3 3
9 Petrol Stripping 1 1 3 4.288 1 4 13
10 Developmental Machine- MMC&LR 1 1 3 4.288 1 4 13
11 Breakdown(from past record) 1 1 5.75 1 6 0
12 Running Problems 1 1 26 1 0 26
_________________________________________________________________________________________________________________________
National Productivity Council, Bangalore.
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 1 F+3 H
Work Centre Carding - - -
1F+2H+1 Flat
Grinder
PF PH PF PH
Frequency/
Month
Crew
Category
WLS No:BSM/W/02
WORK LOAD DETAILS SHEET
Shifts
Present
Manpower
Proposed
Manpower
No of
Machine
Monthly
workload(Hours)
S.
No
Activity Description Time
(in
Hours)
Proposed Method
13 Flat Grinding 20.8
A 130.51 360.90
B 166.4 166.4
C 78.43% 72.30%
D 1 3
E 78.43% 76.52%
Proposed Manpower
The running fitter attends the running problem only in the general shift. The running problem between 5pm to 8 am is attended by production
operator. The fitter is called whenever required depends on the problem. It also found that the running problems are very less and breakdown
is very minimal.
The activity of flat grinders are considered in the proposed method.
Proposed Utilisation(%)
Total Workload per month ( in man hours )
Net Available man-hours per month(8*26*80% = 166.4 hours)
Present Utilisation(%)
_________________________________________________________________________________________________________________________
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________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - 1
Designation Proposed Manpower - - 0
Sl.
No
Crew
Size
Freq/
Month
Basic
Time
(hours)
No of
machin
es
Monthly
Workload
(hours)
1
1 1/24 4.80 26 5.20
2 1 1/24 4.80 26 5.20
3 1 1/24 4.80 26 5.20
4 1 1/24 4.80 26 5.20
A 20.80
B 166.4
E 12.50%
F 0
G 0.00%
Number of carding machine - 26 Nos
It is suggested that flat grinder performs the scheduled works, the operator performs the flat
grinding activity.
Number of stationary flats per machine - 88 nos
The utilisation of flat grinder is only 12.50%. The activity of flat grinder is not time bounded like
machine has to start within given hours. As all the activities are outside work, it does not affect the
machine availability.
Present Utilisation(%)
Proposed Utilisation(%)
Flat Grinding
Remarks:
Activity Description
Remove the stationary flats from flats(88
nos)
Take bare reading and leveling(88 nos)
C
Total Workload per month ( in man hours )
Net Available man-hours per month(8*26*80% = 166.4 hours)
-
-
Grinding of all the flats(88 nos)
Flat Grinder
Clip all the flats(88 nos)
Frequency of flat grinding - once in two years
Proposed Manpower per shift
WLS No:BSM/W/03
BTM
Shifts A B G
Mechanical
WORK LOAD DETAILS SHEET
_______________________________________________________________________________
National Productivity Council, Bangalore.
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 1F+3H
Work Centre
Drawframe
& Simplex
- - - 1F+3H
PF PH PF PH
A Drawframe
1 M/C Cleaning 2 1 2 1.42 11 14 62
a) Allow to run out the material
b) Stop the machine
c) Remove all the cans from machine
d) Put the Rexin and bench on machine
e) Remove the top roll from machine
f) Clean the top clearer cloth
g) Remove the jam of bottom
h) Remove the coiler cover
i) Clean all the coiler
j) Apply grease in bottom roll ,coiler,callender
roll and delivery roll shaft&gearing
k) run the machine
l) Stop the machine
m) remove fly and grease
n) Clean All the rolls and coiler from petrol
o) Apply Chalk powder in bottom roll
,coiler,callender roll and delivery roll shaft
p) Check the machine for any abnormality
q) Put top roll on machine
WLS No:BSM/W/04
WORK LOAD DETAILS SHEET
Shifts
Present
Manpower
Proposed
Manpower
Time
(in
Hours)
S. No Activity Description
Crew Category Monthly
workload(Hours)
Frequency/
Month
No of
Machine
_________________________________________________________________________________________________________________________
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 1F+3H
Work Centre
Drawframe
& Simplex
- - - 1F+3H
PF PH PF PH
WLS No:BSM/W/04
WORK LOAD DETAILS SHEET
Shifts
Present
Manpower
Proposed
Manpower
Time
(in
Hours)
S. No Activity Description
Crew Category Monthly
workload(Hours)
Frequency/
Month
No of
Machine
2 Coiler OH 1/2 1 2 1.42 11 8 16
3 Oil Change 1/2 1 1 1.42 11 8 8
4 Bottom Roll Trueing 1/2 1 1 2.84 11 16 16
a) Allow to run out the material
b) Stop the machine
c) Remove all the cans from machine
d) remove the oil from gear box
e) Open the gearing and coiler
f) Open the gear box
g) Take out the all rolls
h) Clan the roll and slide gearing and Gear box,
coiler with brush and kerosene
i) Check and roll true
j) Check wire rings and balls if faulty then replace
k) Apply grease in coiler
l) Reset the coiler
m) Clan the coiler plate from wall hold compound
n) put all rolls, coiler and gears in machine
o) Apply FCV powder where needed
p) Start the machine
_________________________________________________________________________________________________________________________
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 1F+3H
Work Centre
Drawframe
& Simplex
- - - 1F+3H
PF PH PF PH
WLS No:BSM/W/04
WORK LOAD DETAILS SHEET
Shifts
Present
Manpower
Proposed
Manpower
Time
(in
Hours)
S. No Activity Description
Crew Category Monthly
workload(Hours)
Frequency/
Month
No of
Machine
B Simplex
1 M/C Cleaning 1 1 3 4.49 10 27 135
a) Allow to run out the material
b) Stop the machine
c) Take out all the flyer
d) Raise the pateli
e) Run the machine idle &apply grease in Bottom
roll
f) Clean the Excess grease from bottom roll
g) Raise the top arm and remove the cradle
h) Wash the top apron from surf
i) Refix all the aprons on cradle
j) Apply lubricants on weight chain, lever chain
and lever bush & pateli bush
k) Stop the machine
l) Clean the top and bottom clearer cloth
m) Remove the jam from bottom roll
n) Clean all the gearing
o) Check all the bearing and gears
_________________________________________________________________________________________________________________________
National Productivity Council, Bangalore.
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 1F+3H
Work Centre
Drawframe
& Simplex
- - - 1F+3H
PF PH PF PH
WLS No:BSM/W/04
WORK LOAD DETAILS SHEET
Shifts
Present
Manpower
Proposed
Manpower
Time
(in
Hours)
S. No Activity Description
Crew Category Monthly
workload(Hours)
Frequency/
Month
No of
Machine
p) Clean all the spindle wheel, bobbin wheel
Bobbin rail and Spindle rail& apply grease on
q) Close all the cover
r) clean all the flyer
s) Fit cradle on machine
t) Reset the Arm
u) Start the machine and down the petti
v) Apply spindle oil in spindle
w) Run the machine idle
x) Stop the machine
y) Then reclean all the grease and oil
z) Put flyer on spindle
aa) Clean the flyer with rope and petrol
ab) handover the machine
2 Long Collar Cleaning 1/3 1 3 1.50 10 5 15
a) Allow to run out the material
b) Stop the machine
c) Open the spindle cover
d) Open the spindle and take it out
e) Clean the collar from bottle brush
_________________________________________________________________________________________________________________________
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 1F+3H
Work Centre
Drawframe
& Simplex
- - - 1F+3H
PF PH PF PH
WLS No:BSM/W/04
WORK LOAD DETAILS SHEET
Shifts
Present
Manpower
Proposed
Manpower
Time
(in
Hours)
S. No Activity Description
Crew Category Monthly
workload(Hours)
Frequency/
Month
No of
Machine
f) Remove old oil from spindle housing
g) Put fresh oil
h) Refix the spindle in collar
i) Make them free
j) Set all the spindle wheel
k) Apply grease on spindle and bobbin wheel
l) Close the cover
m) Start the machine
3 Bottom Apron Change 1/9 2 0.25 10 0 1
4 Top Apron Change 1/18 2 0.25 10 0 0.28
5 Middle Arbor Greasing 1/12 2 0.17 10 0 0.28
6 Bottom roll gauge checking & Top arm
pressure setting
1/6 1 1 1.50 10 2 2
a) Allow to run out the material
b) Stop the machine
c) Check the Arm pressure and arm bar
_________________________________________________________________________________________________________________________
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 1F+3H
Work Centre
Drawframe
& Simplex
- - - 1F+3H
PF PH PF PH
WLS No:BSM/W/04
WORK LOAD DETAILS SHEET
Shifts
Present
Manpower
Proposed
Manpower
Time
(in
Hours)
S. No Activity Description
Crew Category Monthly
workload(Hours)
Frequency/
Month
No of
Machine
7 Spindle Trueing 1/6 1 1 1.50 10 2 2
a) Allow to run out the material
b) Stop the machine
c) Take out all the spindle
d) True all the spindle
e) Clean all the long collar
f) Put spindle in collar
g) Make them free
h) Close the cover
i) Apply oil in long collar in running mode
j) Clean all the excess oil in stoppage mode
k) Run the machine
8 Bottom Roll Trueing 1/6 1 1 2.99 10 5 5
a) Allow to run out the material
b) Stop the machine
c) Raise the top Arm
d) Take out the bottom roll
e) Clean all the bottom roll
f) Check all the bearing of bottom roll
g) Make all the true
_________________________________________________________________________________________________________________________
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 1F+3H
Work Centre
Drawframe
& Simplex
- - - 1F+3H
PF PH PF PH
WLS No:BSM/W/04
WORK LOAD DETAILS SHEET
Shifts
Present
Manpower
Proposed
Manpower
Time
(in
Hours)
S. No Activity Description
Crew Category Monthly
workload(Hours)
Frequency/
Month
No of
Machine
h) Fit on the machine
i) Apply grease in all rolls in running mode
j) Clean all the grease with petrol
k) Start the machine
9 Bottom Roll Trueing ( Front & middle) 1/24 1 1 2.99 10 1 1
a) Allow to run out the material
b) Stop the machine
c) Raise the top Arm
d) Take out the bottom roll
e) Clean all the bottom roll
f) Check all the bearing of bottom roll
g) Make all the true
h) Fit on the machine
i) Apply grease in all rolls in running mode
j) Clean all the grease with petrol
k) Start the machine
_________________________________________________________________________________________________________________________
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 1F+3H
Work Centre
Drawframe
& Simplex
- - - 1F+3H
PF PH PF PH
WLS No:BSM/W/04
WORK LOAD DETAILS SHEET
Shifts
Present
Manpower
Proposed
Manpower
Time
(in
Hours)
S. No Activity Description
Crew Category Monthly
workload(Hours)
Frequency/
Month
No of
Machine
10 Developmental Machine(Drawframe 2 1 3 5.99 1 12 36
11 Running work(Draw frame &Simplex)Provided
in the schedule ( 2 days/month)
2 1 3 5.99 1 12 36
C Proposed Method: 2 1 3 5.99 1
12 Activity of Running fitter is divided among
three helpers and one fitter ( 69 hours/month =
17.5 hours fitter & 52.5 hours helpers)
17.50 52.50
A 111.91 335.21
B 166.4 166.4
C 67.25% 67.15%
D 1 3
E 77.77% 77.67%
In this section (Drawframe&Simplex) the fitter % utilisation is very minimal when compared to the other sections. In other section, the total
time of cleaning is approx one hour. In that involvement of fitter is also around 30-40 mins. Whereas in D/F & Simplex Machine cleaning
time is approx 4 hours(D/F) & 6 Hours(Simplex). In this situation, the work of fitter (40 mins) is very minimal.
Total Workload per month ( in man hours )
Net Available man-hours per month(8*26*80% = 166.4 hours)
Present Utilisation(%)
Proposed Manpower
Proposed Utilisation(%)
_________________________________________________________________________________________________________________________
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____________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 1
Designation Proposed Manpower - - - 0
Sl.
No
Crew
Size
Freq/
Month
Basic
Time
(hours)
Monthly
Workload
(hours)
A
1 1 26 0.17 4.33
2 1 26 0.17 4.33
3 1 26 0.30 7.80
B
1 1 26 0.25 6.50
2 1 248 0.03 7.44
3 1 358 0.03 10.74
4 1 4 0.75 3.00
5 1 49 0.50 24.50
A 68.65
B 166.4
E 41.25%
F 0
G 0.00%
Count change = 147/3 = 49
Proposed Manpower per shift
Proposed Utilisation(%)
Remarks:
Aprons Changed = 742/3 = 248
Cots Changed = 1072/3 = 358
Flyer ceramic bush changed = 11/3 = 4
Draw
frame&Simplex
Running Fitter
Activity Description
Count change
Drawframe:
Monitor the sliver @ Cherryhara & LR
Check the stop motion
Change the flyer ceramic bush
The activity is shifted to drawframe mechanical gang and considered there.
Data collected from past record (Sep'11 to Nov'11)
Take the sample for uster % checking to lab, wait
and collect the result
Change the apron
Simplex
Round checkup the machine for problem
Change the Cots
Total Workload per month ( in man hours )
Net Available man-hours per month(8*26*80% = 166.4 hours)
Present Utilisation(%)
WLS No:BSM/W/05
WORK LOAD DETAILS SHEET
BTM
Shifts A B C G
Mechanical
_______________________________________________________________________________
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________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - 1F+1H
Designation Proposed Manpower - - 1F
Sl.
No
Crew
Size
Freq/
Month
Basic
Time
(mins)
No of
machine
s
Monthly
Workload
(mins)
1
1 1 5.00 2 10.00
1 1/3 0.17 21120 1173.33
2 1/3 0.17 10560 586.67
1 1 5.00 2 10.00
2 1/3 0.30 211 21.12
2
1 1/3 15.00 48 240.00
1 1/3 15.00 48 240.00
3
1 1 5.00 2 10.00
1 1/2 0.17 540 45.00
2 1/2 0.17 135 11.25
1 1 5.00 2 10.00
2 1/2 0.30 11 1.62
4
1 1/2 15.00 10 75.00
1 1/2 15.00 10 75.00
5 1
1 1/24 0.12 48 0.23
1 1/24 0.55 21120 484.00
1 1/24 0.23 48 0.47
1 1/24 0.25 48 0.50
1 1/24 0.15 21120 132.00
6 1
1 1/24 0.12 10 0.05
1 1/24 0.55 540 12.38
1 1/24 0.23 10 0.10
1 1/24 0.25 10 0.10
WLS No:BSM/W/06
WORK LOAD DETAILS SHEET
BTM
Shifts A B C G
Mechanical
-
Cots Buffing-Ring Frame
Bring the cots trays from the machine area
Cots Buffer -
Activity Description
Cots Buffing
Room
Buff in the machine(machine cycle
time).Operator work only feeding
Prepare liquimix solution
Apply liquimix on whole sets
Grease the whole sets(50 pieces-19 mins*2crew
Apply liquimix on whole sets
Check the eccentricity machine(parallel done
Keep back the trays to machine area
Grease the whole sets(50 pieces-19 mins*2crew
size)
Second time buffing(25%)
Check the eccentricity machine(parallel done
during buffing)
Remove cots
Remove the bolt from machine
Buff in the machine(machine cycle
time).Operator work only feeding
Second time buffing(25%)
Keep back the trays to machine area
Soak the cots in that overnight&clean
Set the bolt on machine to remove cots
Cots Mounting-Simplex
Fix the new bolt on machine
Remove the bolt from machine
Fix the new bolt on machine
Fix new cots
Set the bolt on machine to remove cots
Remove cots
Prepare liquimix solution
Soak the cots in that overnight&clean
Cots Mounting-Ringframe
Cots Buffing-Simplex
Bring the cots trays from the machine area
_______________________________________________________________________________
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________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - 1F+1H
Designation Proposed Manpower - - 1F
Sl.
No
Crew
Size
Freq/
Month
Basic
Time
(mins)
No of
machine
s
Monthly
Workload
(mins)
WLS No:BSM/W/06
WORK LOAD DETAILS SHEET
BTM
Shifts A B C G
Mechanical
-
Cots Buffer -
Activity Description
Cots Buffing
Room
1 1/24 0.15 540 3.38
7
1 1/60 1.02 33 0.56
1 1/60 0.72 33 0.39
8
1 1/24 10.00 48 20.00
1 1/24 1.02 5280 223.67
1 1/24 2.48 5280 545.60
A 3932.41
B 9984.0
E 19.69%
F 1
G 39.39%
Fix new cots
Fix new cots
Cots Mounting -Drawframe
Remove spindle
Remarks:
Apply fevicol, fix the new cloth & dry
Total Workload per month ( in man mins )
Net Available man-mins per month(480*26*80%= 9984 mins)
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Fix the green cloth on the top roller clearer
Soak the top roller clearer overnight
Remove the old cloth
_______________________________________________________________________________
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 1F+1AF+8H
Work Centre
Ringframe &
TFO
- - - 1F+1AF+8H
PF PH PF PH
A Ringframe
1 M/C Cleaning & Top Apron Change 2 2 8 0.99 48 189.6 758.4
a) Stop the machine
b) Lift out the top roller clearer
c) Lift out the top arm
d) Wrap out the rove bobbins
e) Cleaning of the bobbin holder caps
f) Dismantling of the pnumafil pipe
g) Cleaning of the front, middle & back arbor
h) Cleaning of the L-Bracket, apron bridge bar
and fluted roller
i) Back zone cleaning
j) Cleaning of the lifting, lifting pulley, lappet
rod, poker rod, porker rod tube.
k) Cleaning of the spindle and ring rail
l) Bolster jam cleaning
m) Mantling of the pnumafil pipes
n) Pressing of the top arms
o) Placing of the top roller clearer.
p) Dismantling of the draft gear
No of
Machine
Frequency/
Month
Monthly workload(Hours) Time
(in Hours) S. No Activity Description
Crew Category
WLS No:BSM/W/07
WORK LOAD DETAILS SHEET
Shifts
Present
Manpower
Proposed
Manpower
_________________________________________________________________________________________________________________________
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 1F+1AF+8H
Work Centre
Ringframe &
TFO
- - - 1F+1AF+8H
PF PH PF PH
No of
Machine
Frequency/
Month
Monthly workload(Hours) Time
(in Hours) S. No Activity Description
Crew Category
WLS No:BSM/W/07
WORK LOAD DETAILS SHEET
Shifts
Present
Manpower
Proposed
Manpower
q) Cleaning & Checking of the draft gear
r) Greasing of the machine & motor pulley
s) Checking of roving guide and spacer,
t) Cleaning of the gutter
Top Apron Change
a) Stop the machine & Dismantle the cradles
b) Removal of the old aprons
c) Insert the new apron in the cradles
d) Insert the cradle and start the machine
2 Spindle Oil Topping 1/4 8 0.083 48 0 8
a) Removal of the spindle
b) Dropping of the oil in to the spindles
c) Placing of the spindles on its position
3 Spindle.Oil Change 1/12 2 8 0.25 48 2 8
a) Removal of the spindle
b) Replacing of the oil in to the spindles with
the help of oiling machine
c) Placing of the spindles on its position
_________________________________________________________________________________________________________________________
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 1F+1AF+8H
Work Centre
Ringframe &
TFO
- - - 1F+1AF+8H
PF PH PF PH
No of
Machine
Frequency/
Month
Monthly workload(Hours) Time
(in Hours) S. No Activity Description
Crew Category
WLS No:BSM/W/07
WORK LOAD DETAILS SHEET
Shifts
Present
Manpower
Proposed
Manpower
4 Bottom Apron Change 1/8 0 8 0.25 48 0 12
a) Dismantling of the bridge bar
b) Removal of the old aprons
c) Insert the new aprons
d) Mantling of the bridge bar
6 Middle Arbor Greasing 1/12 0 8 0.153 48 0 4.89
a) Open of the arbor
b) Greasing of the arbor
c) Petrol wash of the arbor
7 Rings Change-Texmaco Developmental 2 2 8 0.79 1 3.2 12.6
8 Rings Change-LR Developmental m/c 2 2 8 0.79 1 3.16 12.64
9 Spindle Change 1/120 0 4** 9.5 50 0 7.0
10 Lifting OH 1/24 0 3** 9.5 48 0 16.8
B TFO
1 M/C Cleaning 1 2 8 1.02 48 98.04 392.16
a) Allow to run out the material
_________________________________________________________________________________________________________________________
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 1F+1AF+8H
Work Centre
Ringframe &
TFO
- - - 1F+1AF+8H
PF PH PF PH
No of
Machine
Frequency/
Month
Monthly workload(Hours) Time
(in Hours) S. No Activity Description
Crew Category
WLS No:BSM/W/07
WORK LOAD DETAILS SHEET
Shifts
Present
Manpower
Proposed
Manpower
b) Stop the machine
c) Clean the adaptor
d) Down the cradle and clean them
e) Remove jam from drum &PTR and clean
them
f) Clean the Pig tail, J.Pulley.
g) Remove jam from J.Pulley and Drum Pulley
d) Clean separator from surf and Dhoti
f) Take out the pot
g) Clean the pot from surf and dhoti
h) Take out the spindle
i) Clean the spindle from dhoti surf
j) Clean the thread guide
k) Clean the beam
l) Clean the drum pulley
m) Put spindle
n) Put pot
o) Reset the setting of pot
p) Clean and check all the gearing and if found
faulty the informed to foreman
_________________________________________________________________________________________________________________________
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 1F+1AF+8H
Work Centre
Ringframe &
TFO
- - - 1F+1AF+8H
PF PH PF PH
No of
Machine
Frequency/
Month
Monthly workload(Hours) Time
(in Hours) S. No Activity Description
Crew Category
WLS No:BSM/W/07
WORK LOAD DETAILS SHEET
Shifts
Present
Manpower
Proposed
Manpower
q) Apply grease on gearing
r) Close the cover
s) Start the machine
t) Clean the break
u) clean the machine
v) Handover to production
2 Spindle Oil Topping 1/2 1 1 0.25 48 6 6
a) Stop the machine
b) Taken out the pot
c) Taken out the spindle
d) Topping done
e) Put Spindle
f) Put Pot
g) Start the machine
3 Spindle Oil Change 1/12 1 1 0.50 48 2 2
a) Stop the machine
b) Taken out the pot
c) Taken out the spindle
_________________________________________________________________________________________________________________________
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 1F+1AF+8H
Work Centre
Ringframe &
TFO
- - - 1F+1AF+8H
PF PH PF PH
No of
Machine
Frequency/
Month
Monthly workload(Hours) Time
(in Hours) S. No Activity Description
Crew Category
WLS No:BSM/W/07
WORK LOAD DETAILS SHEET
Shifts
Present
Manpower
Proposed
Manpower
d) Clean the spindle
e) Remove burnt oil from bolster
f) Put fresh oil
g) Put Spindle
h) Put Pot
i) Start the machine
4 Spindle Bearing Greasing-VJ 1/12 1 1 0.25 38 0.792 0.792
a) Allow to run out the material
b) Stop the machine
c) Remove pot and spindle
d) Clean the spindle and pot
e) Apply grease in spindle bearing
f) Put spindle
g) Put pot
h) Start the machine
5 Spindle Bearing Greasing-Prerna 1/4 1 1 0.25 10 0.625 0.625
a) Allow to run out the material
b) Stop the machine
_________________________________________________________________________________________________________________________
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 1F+1AF+8H
Work Centre
Ringframe &
TFO
- - - 1F+1AF+8H
PF PH PF PH
No of
Machine
Frequency/
Month
Monthly workload(Hours) Time
(in Hours) S. No Activity Description
Crew Category
WLS No:BSM/W/07
WORK LOAD DETAILS SHEET
Shifts
Present
Manpower
Proposed
Manpower
c) Remove pot and spindle
d) Clean the spindle and pot
e) Apply grease in spindle bearing
f) Put spindle
g) Put pot
h) Start the machine
A 305.38 1241.95
B 166.4 166.4
C 91.76% 93.30%
D 2 8
E 91.76% 98.31%
* Out of three helpers, one are from cleaning gang.
** Out of four helpers, two are from cleaning gang.
Net Available man-hours per month(8*26*80% = 166.4 hours)
Present Utilisation(%)
Proposed Manpower
Proposed Utilisation(%)
Total Workload per month ( in man hours )
_________________________________________________________________________________________________________________________
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 2 F+ 2 H
Work Centre
Ringframe &
TFO
- - - 2 F+ 2 H
PF PH PF PH
1 Draft Gear Overhauling 1/6 2 2 2.4 50 39.57 39.57
a) Stop the machine and dismantle the whole draft
gear system
b) Washing of the gears, bearing, stud and stud key
with kerosene oil
c) Mantling of the whole draft gear system
d) Start the machine and checking the gear system
2 Heart Cam Overhauling(Texmaco M/c only)
1/3 1 1 1.2 32 12.66 12.66
a) Stop the machine and dismantling of the heart cam
assembly
b) Checking and cleaning of the heart cam, heart cam
shaft, ball bearings, plate wheel, ratchet pawl &
ratchet pawl stud c) Mantling of the heart cam assembly
d) Start the machine and check the movement of the
heart cam
WLS No:BSM/W/08
WORK LOAD DETAILS SHEET
Shifts
Present Manpower
Proposed
Manpower
Frequency/
Month
Crew Category
S. No Activity Description
Time
(in Hours)
No of
Machine
Monthly
workload(Hours)
_________________________________________________________________________________________________________________________
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 2 F+ 2 H
Work Centre
Ringframe &
TFO
- - - 2 F+ 2 H
PF PH PF PH
WLS No:BSM/W/08
WORK LOAD DETAILS SHEET
Shifts
Present Manpower
Proposed
Manpower
Frequency/
Month
Crew Category
S. No Activity Description
Time
(in Hours)
No of
Machine
Monthly
workload(Hours)
3 Heart Cam Overhauling-Develop-Texmaco
1/3 2 2 1.0 1 0.67 0.67
4 J.P.Ball Brg. Greasing 1/12 2 2 2.4 48 18.992 18.992
a) Stop the machine and dismantling of the jockey
pulley system
b) Greasing of the jockey pulley
c) Mantling of the jockey pulley
d) Dismantling of the cover of the pedestal
e) Cleaning of the pedestal
f) Greasing of the pedestal
g) Mantle the cover of the pedestal
h) Setting of the jockey pulley, T.R Pulley and drum
pulley and tap
i) Start the machine and check the machine
5 J.P.Ball Brg. Greasing-Texmaco Developmental
m/c
1/12 2 2 0.5 1 0.08 0.08
6 J.P.Ball Brg. Greasing-LR Developmental m/c
1/12 2 2 1.0 1 0.17 0.17
_________________________________________________________________________________________________________________________
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 2 F+ 2 H
Work Centre
Ringframe &
TFO
- - - 2 F+ 2 H
PF PH PF PH
WLS No:BSM/W/08
WORK LOAD DETAILS SHEET
Shifts
Present Manpower
Proposed
Manpower
Frequency/
Month
Crew Category
S. No Activity Description
Time
(in Hours)
No of
Machine
Monthly
workload(Hours)
7 Bottom Roll Truing 1/12 2 2 7.1 48 56.98 56.98
a) Open of the bottom roll bearings of the reserved
b) Washing of the bottom roll with petrol with the
c) Fitting of the bearing in the bottom roll
d) Roll to roll joining
e) Truing of the bottom roll
f) Stop the one side of the machine and remove the
bottom roll from the machine
g) Mantling of the new trued roll to the machine
h) Start the that side of the machine
i) Repeat the steps from a to h for other side of the
machine
8 Bottom Roll Truing-Texmaco Developmental
m/c
1/12 2 2 1.0 1 0.17 0.17
9 Bottom Roll Truing-LR Developmental m/c
1/12 2 2 4.0 1 0.67 0.67
10 Lappet Hook Change 1/24 2 2 2.4 1 0.20 0.20
_________________________________________________________________________________________________________________________
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 2 F+ 2 H
Work Centre
Ringframe &
TFO
- - - 2 F+ 2 H
PF PH PF PH
WLS No:BSM/W/08
WORK LOAD DETAILS SHEET
Shifts
Present Manpower
Proposed
Manpower
Frequency/
Month
Crew Category
S. No Activity Description
Time
(in Hours)
No of
Machine
Monthly
workload(Hours)
a) Stop the machine and dismantling of the lappet
hook
b) Rough fitting of the new lappet hooks
c) Lappet gauge of the lappet hook
11 Lappet Hook Change-Texmaco Developmental
m/c
1/24 2 2 1.0 1 0.083 0.083
12 Lappet Hook Change-LR Developmental m/c
1/24 2 2 1.0 1 0.083 0.083
13 Lifting OH 1/24 2 3* 7.1 48 28.488 32.4
a) Stop the machine and dismantle the lappet rail
b) Dismantling of the separator
c) Dismantling of the ring rail
d) Dismantling of Lifting pulley, lappet rod, pocket
rod, pocker rod tube
e) Dismantling of the ball bearing of the lifting pulley
f) Washing of lappet rod, pocker rod tube, ring rail
head bracket
g) Mantling of the lifting pulley with new bearing
_________________________________________________________________________________________________________________________
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 2 F+ 2 H
Work Centre
Ringframe &
TFO
- - - 2 F+ 2 H
PF PH PF PH
WLS No:BSM/W/08
WORK LOAD DETAILS SHEET
Shifts
Present Manpower
Proposed
Manpower
Frequency/
Month
Crew Category
S. No Activity Description
Time
(in Hours)
No of
Machine
Monthly
workload(Hours)
h) Complete assembling of the lappet rod, pocker rod
tube, ring rail head bracket
i) Ring rail fitting & lappet rail fitting
j) Ring rail height gauge and lappet rail height gauge
k) Spindle gauge and lappet gauge
l) Fly catcher gauge
m) Separator fitting and start the machine
14 Lifting OH-Texmaco Developmental m/c 1/24 2 2 4.0 1 0.33 0.33
15 Lifting OH-LR Developmental m/c 1/24 2 2 4.0 1 0.33 0.33
16 Spindle Gauge 1/8 2 2 2.4 48 28.488 28.488
a) Stop the machine and dismantling of the separator
b) Cleaning of the poker tube and lappet rod
c) Ring rail height gauge
d) Lappet rail height gauge
e) Spindle gauge
f) Lappet gauge
g) Fly catcher gauge
h) Fitting of the separator and start the machine
_________________________________________________________________________________________________________________________
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 2 F+ 2 H
Work Centre
Ringframe &
TFO
- - - 2 F+ 2 H
PF PH PF PH
WLS No:BSM/W/08
WORK LOAD DETAILS SHEET
Shifts
Present Manpower
Proposed
Manpower
Frequency/
Month
Crew Category
S. No Activity Description
Time
(in Hours)
No of
Machine
Monthly
workload(Hours)
17 Spindle Gauge-Texmaco Developmental m/c 1/8 2 2 0.5 1 0.125 0.125
18 Spindle Gauge-LR Developmental m/c 1/8 2 2 1.0 1 0.25 0.25
19 Rings Change 1/24 2 2 7.1 48 28.49 28.49
a) Stop the machine and dismantle the separator
b) Remove the ring rail and cleaning of the ring rail
c) Change the ring with new one
d) Cleaning of the lappet rod & pocker rod tube
e) Fitting of the ring rail
f) Ring rail height gauge
g) Lappet rail height gauge
h) Rough ring gauge
i) Final ring gauge
j) Lappet hook gauge
k) Fly catcher gauge
l) Fitting of the separator
m) Start the machine and check the movement
20 Rings Change-Texmaco Developmental m/c 1/24 2 2 1.0 1 0.083 0.083
21 Rings Change-LR Developmental m/c 1/24 2 2 1.5 1 0.125 0.125
_________________________________________________________________________________________________________________________
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 2 F+ 2 H
Work Centre
Ringframe &
TFO
- - - 2 F+ 2 H
PF PH PF PH
WLS No:BSM/W/08
WORK LOAD DETAILS SHEET
Shifts
Present Manpower
Proposed
Manpower
Frequency/
Month
Crew Category
S. No Activity Description
Time
(in Hours)
No of
Machine
Monthly
workload(Hours)
22 Spindle Change 1/120 2 4** 7.1 50 5.935 6.75
a) Stop the machine and dismantle the ABC Ring rail
b) Dismantle the separator
c) Loose the bolster
d) Bolster open with spindle
e) Fitted the new bolster with spindle
f) Tight the bolster
g) Open the spindle
h) Oiling the bolster
i) Fitting the spindle in to the bolster
j) Ring rail height gauge
k) Lappet Height gauge
l) ABC ring rail height gauge and fitting
m) Dismantling of the ABC rings rail
n) Ring gauge
o) Lappet gauge
p) Fly Catcher gauge
q) Fitting of the separator
r) ABC ring rail fitting and start the machine
_________________________________________________________________________________________________________________________
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 2 F+ 2 H
Work Centre
Ringframe &
TFO
- - - 2 F+ 2 H
PF PH PF PH
WLS No:BSM/W/08
WORK LOAD DETAILS SHEET
Shifts
Present Manpower
Proposed
Manpower
Frequency/
Month
Crew Category
S. No Activity Description
Time
(in Hours)
No of
Machine
Monthly
workload(Hours)
A 222.96 227.69
B 166.4 166.4
C 67.00% 68.42%
D 2 2
E 67.00% 68.42%
** Out of four helpers, two are from cleaning gang.
Proposed Manpower
Proposed Utilisation(%)
Present Utilisation(%)
* Out of three helpers, one are from cleaning gang.
Total Workload per month ( in man hours )
Net Available man-hours per month(8*26*80% = 166.4 hours)
_________________________________________________________________________________________________________________________
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________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - 1
Designation Proposed Manpower - - 1
Sl.
No
Crew
Size
Freq/
Month
Basic
Time
(hours)
No of
machin
es
Monthly
Workload
(hours)
1 1 2 0.35 48 33.60
2 1 2 0.25 48 24.00
3 1 7.75
4 1
A 65.35
B 166.4
E 39.27%
F 1
G 39.27% Proposed Utilisation(%)
Total Workload per month ( in man hours )
Net Available man-hours per month(8*26*80% = 166.4 hours)
Present Utilisation(%)
Proposed Manpower per shift
Remarks:
-
Duct Fitter
G
Major idle attend
Ringframe
Activity Description
Mechanical
-
Assist the Foreman in attending breakdown
WLS No:BSM/W/09
WORK LOAD DETAILS SHEET
BTM
Shifts A B C
Clean the Pn pipe,Clean all the duct
To check the all spindle lock
_______________________________________________________________________________
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 2 F+3 H
Work Centre
Autoconer &
Cheesewinding
- - - 2F+3 H
PF PH PF PH
A Autowinding
1 M/C Cleaning & Cleaning of Base Adaptor 2 1 3 1.19 7 16.59 49.77
a) Stop the machine
b) Dismantle the magazine
c) Cleaning of the machine with the air pressure
d) Cutting of the adopter jam
e) Conveyor belt plate is removed from the machine for
cleaning
f) Cutting of the jam on the conveyor belt pulley
g) Cleaning of the Jali
d) Cleaning of the head stock
f) Checking of the suction and conveyor belt
g) Cutting of the jam on material trolley or repairing of the
bearing in case jammed
h) Checking of the machine as per the check sheet and
attend if found any abnormality.
2 Winding. Head Cleaning & Oiling 1/3 1 3 0 7 0.92 2.77
Open the cover
WLS No:BSM/W/10
WORK LOAD DETAILS SHEET
Shifts
Present Manpower
Proposed Manpower
Time
(in
Hours)
S.
N
o
Activity Description
Crew Category
Frequency/
Month
No of
Machine
Monthly
workload(Hours)
_________________________________________________________________________________________________________________________
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 2 F+3 H
Work Centre
Autoconer &
Cheesewinding
- - - 2F+3 H
PF PH PF PH
WLS No:BSM/W/10
WORK LOAD DETAILS SHEET
Shifts
Present Manpower
Proposed Manpower
Time
(in
Hours)
S.
N
o
Activity Description
Crew Category
Frequency/
Month
No of
Machine
Monthly
workload(Hours)
Clean the Head by Air pressure
Remove any abnormality if found
Grease at necessary parts
Close the cover
3 Suction Arm Setting
Setting check 1/3 1 3 0 7 0.58 1.75
4 Gripper arm Setting 1/3 1 3 0 7 0.58 1.75
Setting check
5 Yarn Trap OH 1/4 3 3 7 0.00 16.59
Open the yarn trap
Open the yarn trap assembly
Clean the bracket the Gear
Clean the assembly and yarn trap
Silicon oil added on yarn trap assembly rod
Refix the yarn trap assembly
Fix the assembly on machine
_________________________________________________________________________________________________________________________
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 2 F+3 H
Work Centre
Autoconer &
Cheesewinding
- - - 2F+3 H
PF PH PF PH
WLS No:BSM/W/10
WORK LOAD DETAILS SHEET
Shifts
Present Manpower
Proposed Manpower
Time
(in
Hours)
S.
N
o
Activity Description
Crew Category
Frequency/
Month
No of
Machine
Monthly
workload(Hours)
Fix the yarn trap on machine
6 Splicer Servicing 1/4 3 3 7 0.00 16.59
Open the splicer
Open the cover
Open the introducer
Clean the introducer
Open the preparatory of splicer
Clean the Splicer
Check the chamber cover and chamber cover spring
Assemble the splicer
Fit on spindle
7 Magazine cover cleaning 1/6 1 3 1 7 0.81 2.42
Remove the magazine
Remove the magazine cover
clean the magazine cover assembly with petrol
Grease on magazine cover rod and spring
Clean the magazine cover
_________________________________________________________________________________________________________________________
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 2 F+3 H
Work Centre
Autoconer &
Cheesewinding
- - - 2F+3 H
PF PH PF PH
WLS No:BSM/W/10
WORK LOAD DETAILS SHEET
Shifts
Present Manpower
Proposed Manpower
Time
(in
Hours)
S.
N
o
Activity Description
Crew Category
Frequency/
Month
No of
Machine
Monthly
workload(Hours)
Fix the magazine cover
Mix the magazine
8 Cradle setting 1/6 2 1 7 0.00 1.61
Stop the machine
loose the bolt
Put the cone
Reset the gauge by 5 mm on base side
Reset the gauge by 4 mm nose side
Tight the bolt
start the machine
9 Bobbin Peg Overhauling 1/4 3 2 7 0.00 8.30
Open the bolt
Open the bobbin peg
cut the jam
Clean the bush of bobbin peg lever
Fix the bobbin peg
Tight the bolt
_________________________________________________________________________________________________________________________
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 2 F+3 H
Work Centre
Autoconer &
Cheesewinding
- - - 2F+3 H
PF PH PF PH
WLS No:BSM/W/10
WORK LOAD DETAILS SHEET
Shifts
Present Manpower
Proposed Manpower
Time
(in
Hours)
S.
N
o
Activity Description
Crew Category
Frequency/
Month
No of
Machine
Monthly
workload(Hours)
10 Duct Cleaning 1/6 2 4 2 7 3.69 7.37
Stop the machine
Remove the magazine
Close the Air pressure
Open the bolt of pressure pipe
Lift the pressure pipe
Open the duct chamber
Remove the support of duct
Open the joint
Remove the economizer with Allen key
Clean the duct
Remove the pipe
Clean the economizer
Clean the pipe
Refit the duct
11 Suction arm OH 1/12 2 4 1 7 1.61 3.23
Stop the machine
_________________________________________________________________________________________________________________________
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 2 F+3 H
Work Centre
Autoconer &
Cheesewinding
- - - 2F+3 H
PF PH PF PH
WLS No:BSM/W/10
WORK LOAD DETAILS SHEET
Shifts
Present Manpower
Proposed Manpower
Time
(in
Hours)
S.
N
o
Activity Description
Crew Category
Frequency/
Month
No of
Machine
Monthly
workload(Hours)
Open the winding head
Open the fitting
Open the suction arm
Open the lock of fitting
taken out the shaft of fitting
Clean the all the suction arm assembly
Clean the fitting and suction arm with surf
Added silicon oil
Refix the suction arm assbly
Fit it on the Suction arm and fitting
Rest the setting of suction arm
Start the machine
12 Clutch OH 1/12 2 4 2 7 1.84 3.69
Stop the machine
open the cover
remove the clutch belt
Open the clutch bolt
Take out the clutch
_________________________________________________________________________________________________________________________
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 2 F+3 H
Work Centre
Autoconer &
Cheesewinding
- - - 2F+3 H
PF PH PF PH
WLS No:BSM/W/10
WORK LOAD DETAILS SHEET
Shifts
Present Manpower
Proposed Manpower
Time
(in
Hours)
S.
N
o
Activity Description
Crew Category
Frequency/
Month
No of
Machine
Monthly
workload(Hours)
Clean the clutch with petrol
Apply grease on clutch
Clean the base of clutch
Fit the clutch and
Fit the Belt
Reset the clutch
Start the machine
13 Splicer OH 1/12 2 4 2 7 1.84 3.69
Stop the machine
Open the splicer pipe
Open the splicer
Open the splicer cover
Clean the splicer with Petrol
Apply OKS 475 Hs grease on Splicer
Close the cover
Fix splicer on the machine & pipe
14 Tension Disc Clg ,Setting & OH 1/6 2 4 1 7 1.84 3.69
_________________________________________________________________________________________________________________________
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 2 F+3 H
Work Centre
Autoconer &
Cheesewinding
- - - 2F+3 H
PF PH PF PH
WLS No:BSM/W/10
WORK LOAD DETAILS SHEET
Shifts
Present Manpower
Proposed Manpower
Time
(in
Hours)
S.
N
o
Activity Description
Crew Category
Frequency/
Month
No of
Machine
Monthly
workload(Hours)
Open the tension assly
Open the tension disc ,piston
Clean the tension disc and piston
Apply oil on piston
Fix the disc and piston in tension assembly
Clean the tension assembly
Fix on machine
15 Tension Assembly Clg & Oiling 1/12 2 4 1 7 0.92 1.84
Open the tension assly
Open the tension disc ,piston
Clean the tension disc and piston
Apply oil on piston
Fix the disc and piston in tension assembly
Clean the tension assembly
Fix on machine
16 Adaptor Greasing 1/6 1 3 1 7 0.92 2.77
Remove the adaptor
_________________________________________________________________________________________________________________________
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 2 F+3 H
Work Centre
Autoconer &
Cheesewinding
- - - 2F+3 H
PF PH PF PH
WLS No:BSM/W/10
WORK LOAD DETAILS SHEET
Shifts
Present Manpower
Proposed Manpower
Time
(in
Hours)
S.
N
o
Activity Description
Crew Category
Frequency/
Month
No of
Machine
Monthly
workload(Hours)
Clean the spring
Clean the adaptor
Clean the machine arm
Nose side jam removal
Fix it back on machine
B Cheese Winding
1 M/C Cleaning with Upper & Lower Guide pulley
Oiling
2 1 3 2 7 33.71 101.12
a) Allow to run out the material
b) Stop the machine
c) Remove the Swing plate and Swing plate cover
d) Remove the jam from Drum & Drum Shaft
e) Remove jam from adaptor
f) Remove the jam of stop motion shaft
g) Clean the whole machine from bottle brush
d) Open the upper and lower guide pulley
f) Clean the upper and lower guide pulley
_________________________________________________________________________________________________________________________
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 2 F+3 H
Work Centre
Autoconer &
Cheesewinding
- - - 2F+3 H
PF PH PF PH
WLS No:BSM/W/10
WORK LOAD DETAILS SHEET
Shifts
Present Manpower
Proposed Manpower
Time
(in
Hours)
S.
N
o
Activity Description
Crew Category
Frequency/
Month
No of
Machine
Monthly
workload(Hours)
g) Apply oil and fit on the machine of both the guide pulley
h) Lubrication on all the points
i) Complete all the missing spare
j) Fix the swing plate and swing plate cover on machine
k) Check all the belts and pulley
l) Start the machine and handover it to Production
2 Drum shaft brg. Greasing 1/6 1 3 6 7 7.49 22.47
a) Allow to run out the material
b) Stop the machine
c) Loose all the drums
d) shift the drums
e) Open the bearing cover
f) Taken out the burnt grease
g) Put fresh grease
d) Check all the bearing if found faulty then replace
f) Close all the bearing cover
g) Set the cradle and drum
_________________________________________________________________________________________________________________________
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 2 F+3 H
Work Centre
Autoconer &
Cheesewinding
- - - 2F+3 H
PF PH PF PH
WLS No:BSM/W/10
WORK LOAD DETAILS SHEET
Shifts
Present Manpower
Proposed Manpower
Time
(in
Hours)
S.
N
o
Activity Description
Crew Category
Frequency/
Month
No of
Machine
Monthly
workload(Hours)
h) Start the machine for 5 min
i) Stop the machine
j)
Then clean the drum and bearing cover with petrol for
removing the greasing
k) Start the machine and handover it to Production
3 Yarn Path Setting 1/3 2 3 7 0.00 14.98
a) Check the yarn path
b) If found any problem then reset them
4 Adopter Greasing & Drum cradle setting 1/3 1 2 7 0.00 5.15
a) Allow to run out the material
b) Stop the machine
c) Fit the cheese in Cradle & check
d) If faulty then reset
e) Start the machine and handover it to Production
5 Drop Needle Change 1/10 3 3 7 0.00 6.74
_________________________________________________________________________________________________________________________
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 2 F+3 H
Work Centre
Autoconer &
Cheesewinding
- - - 2F+3 H
PF PH PF PH
WLS No:BSM/W/10
WORK LOAD DETAILS SHEET
Shifts
Present Manpower
Proposed Manpower
Time
(in
Hours)
S.
N
o
Activity Description
Crew Category
Frequency/
Month
No of
Machine
Monthly
workload(Hours)
6 Yarn guide hook 1/10 3 3 7 0.00 6.74
7 Developmental Machine-Cone Winding 1 1 3 6 1 6.42 19.26
8 Developmental Machine-SSM(Fibre dyeing) 1 3 6 1 0.00 19.26
9 Developmental Machine-PS Metler&Classmate 1 1 3 6 1 6.42 19.26
10 Breakdown Works 1 1 5 4.75 0.00
11 Attend idle spindle(Autoconer&Cheesse winding) 26 1 2 52.00 0.00
A 142.94 342.79
B 166.4 166.4
C 42.95% 68.67%
D 2 3
E 42.95% 68.67%
Total Workload per month ( in man hours )
Net Available man-hours per month(8*26*80% = 166.4 hours)
Present Utilisation(%)
Proposed Manpower
Proposed Utilisation(%)
_________________________________________________________________________________________________________________________
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________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - 1
Designation Proposed Manpower - - 0
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(mins)
No of
machin
es
Total
Workloa
d (mins)
1
1 1 3.95 22 86.96
2
1 1 3.68 10 36.81
3
1 1 3.87 7 27.07
4
1 1 3.91 9 35.19
5 1 1 112.50 1 112.50
A 174.76
B 360.0
E 48.55%
F 0
G 0.00%
B C
OHB Fitter -
Activity Description
Autoconer,Chee
sewinding,TFO
Net Available man-mins per shift(480*80% = 360 mins)
Present Utilisation(%)
Stop the OHTC,Clean the waste box of
OHTC,remove the dust accumulated, clean the filter
with emery sheet, Clean the outer surface of OHTC
using cloth,brush,Check the suction of OHTC,clean
the fly in the rail, check whole the waste discharge
Festo
Remarks:
Stop the OHTC,Clean the waste box of
OHTC,remove the dust accumulated, clean the filter
with emery sheet, Clean the outer surface of OHTC
using cloth,brush,Check the suction of OHTC,clean
the fly in the rail, check whole the waste discharge
system
WLS No: BSM/W/11
WORK LOAD DETAILS SHEET
BTM
Shifts A
Jacobi
Stop the OHTC,Clean the waste box of
OHTC,remove the dust accumulated, clean the filter
with emery sheet, Clean the outer surface of OHTC
using cloth,brush,Check the suction of OHTC,clean
the fly in the rail, check whole the waste discharge
system
Autoconer
Cheesewinding/Rewinding
G
-
Mechanical
Overhaul the OHTC machine(once in two month)
Proposed Utilisation(%)
Total Workload per shift ( in man mins)
Proposed Manpower per shift
Stop the OHTC,Clean the waste box of
OHTC,remove the dust accumulated, clean the filter
with emery sheet, Clean the outer surface of OHTC
using cloth,brush,Check the suction of OHTC,clean
the fly in the rail, check whole the waste discharge
system
_______________________________________________________________________________
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________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - 1
Designation Proposed Manpower - - 0
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(mins)
No of
machin
es
Total
Workloa
d (mins)
B C
OHB Fitter -
Activity Description
Autoconer,Chee
sewinding,TFO
WLS No: BSM/W/11
WORK LOAD DETAILS SHEET
BTM
Shifts A G
-
Mechanical
No of
machines Area
4 TFO
3 Unit-3
15 R/F
1 Winding
Cheese Winding - 5 nos
Ring frame(unit-2) - 5 nos
Ring frame(unit-1) - 7 nos
1
Festo
Unit-3
R/F
Instead of providing one separate personnel for OHTC maintenance with 51.06% utilisation, it is
recommended that the activity could be performed by the respective section's maintenance gang. It
increases the respective gang utilisation and reduces the separate manpower required.
Total OHTC in BTM
Savio- 8 Nos
TFO (unit1 &2) - 8 nos
No of
machines
TFO
Ring frame(unit-3) - 8 nos
TFO(unit-3) - 7 Nos
Leewa
Jacobi
Area
4
1
5
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 1 F+ 1 H
Work Centre TFO - - - 1 F+ 1 H
PF PH PF PH
1 Gear Oil Change (VJ - 38 M/cs) 1/12 1 1 1.00 38 3.17 3.17
a) Stop the machine
b) Open the cover of gear box
c) Remove old oil
d) Clean all the gears
e) Check all the gears
f) Put fresh oil
g) Check the oil pump
d) Close the cover
f) stop the machine
g) Stop motion, Dropper
2 Gear Oil Change(PRN-10 M/c) 1/6 1 1 1.00 10 1.67 1.67
a) Stop the machine
b) Open the cover of gear box
c) Remove old oil
d) Clean all the gears
e) Check all the gears
f) Put fresh oil
g) Check the oil pump
Monthly
workload(Hours)
Time
(in Hours)
Proposed
Manpower
Activity Description
Crew
Category
WLS No:BSM/W/12
WORK LOAD DETAILS SHEET
Shifts
Present
Manpower
S.
No
Frequency/
Month
No of
Machine
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Department BTM A B C G
Section Mechanical - - - 1 F+ 1 H
Work Centre TFO - - - 1 F+ 1 H
PF PH PF PH
Monthly
workload(Hours)
Time
(in Hours)
Proposed
Manpower
Activity Description
Crew
Category
WLS No:BSM/W/12
WORK LOAD DETAILS SHEET
Shifts
Present
Manpower
S.
No
Frequency/
Month
No of
Machine
d) Close the cover
f) stop the machine
3 Stop motion, dropper setting, Adopter Greasing
Setting
1/6 1 1 1.81 48 14.44 14.44
a) Allow to run out the material
b) Stop the machine
c) Take out the all adaptor
d) Clean all the adoptor&Cradle
e) Apply grease in cradle
f) Pur adaptor in cradle
g) Start the machine
d) Down all the dropper wire
f) Check the stop motion and reset stop motion
g) Start the machine
5 T.R. & P.T.R. Greasing 1/6 1 1 0.76 48 6.06 6.06
a) Allow to run out the material
b) Stop the machine
c) Clean burnt grease from TR&PTR
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 1 F+ 1 H
Work Centre TFO - - - 1 F+ 1 H
PF PH PF PH
Monthly
workload(Hours)
Time
(in Hours)
Proposed
Manpower
Activity Description
Crew
Category
WLS No:BSM/W/12
WORK LOAD DETAILS SHEET
Shifts
Present
Manpower
S.
No
Frequency/
Month
No of
Machine
d) Open all nipple
e) Apply fresh grease from pump in TR&PTR
f) Tight the nipple
g) Start the machine
h) Clean all the excess grease
i) Handover the machine to production
6 Tin Roll Bearing Greasing(Only VJ-38 M/cs) 1/6 1 1 1.44 38 9.15 9.15
a) Stop the machine
b) Open the nipple
c) Apply grease
d) Tight the nipple
e) Start the machine
f) Clean all the excess grease
g) Handover the machine to production
7 Belt Guide roller Greasing(Only PRN-10 M/cs) 1/6 1 1 2.17 10 3.61 3.61
a) Stop the machine
b) Allow to run out the material
c) Remove the nipple from guide roller
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 1 F+ 1 H
Work Centre TFO - - - 1 F+ 1 H
PF PH PF PH
Monthly
workload(Hours)
Time
(in Hours)
Proposed
Manpower
Activity Description
Crew
Category
WLS No:BSM/W/12
WORK LOAD DETAILS SHEET
Shifts
Present
Manpower
S.
No
Frequency/
Month
No of
Machine
d) Check all the duide pulley if faulty then replace
e) Apply grease in all guide rolls, Tension pulley and
main pulley
f) Start the machine
8 Thread guide Setting, Cradle, Drum Setting 1/6 1 1 2.17 48 17.33 17.33
a) Allow to run out the material
b) Stop the machine
c) Insert cone in cradle
d) Down the cradle on drum
e) Set the cradle and drum
f) Set the thread guide in middle portion of drum
g) Check the setting through yarn from trum to thread
guide
h) Start the machine
9 Jokey Pulley Greasing
1/12 1 1 1.00 48 4.00 4.00
a) Stop the machine
b) Apply grease in j.Pulley through pump and nipple
c) Start the machine
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 1 F+ 1 H
Work Centre TFO - - - 1 F+ 1 H
PF PH PF PH
Monthly
workload(Hours)
Time
(in Hours)
Proposed
Manpower
Activity Description
Crew
Category
WLS No:BSM/W/12
WORK LOAD DETAILS SHEET
Shifts
Present
Manpower
S.
No
Frequency/
Month
No of
Machine
10 Gear Overhauling 1/12 1 1 2.89 48 11.55 11.55
a) Stop the machine
b) Take out all the gears and bearing and stud
c) Clean all the gears stud and bearings
d) Check and replace all the defective gears stud and
bearing
e) Clean all the gear end
f) Put grease in stud
g) Fix all the gears
d) Apply gears on all gears
f) Start the machine and check for abnormal sound
g) Close the cover
h) Handover to production
11 Pig tail Setting 1/12 1 1 2.89 48 11.55 11.55
a) Stop the machine
b) Remove the material from Pigtail
c) Tie dori from off end to gear end
d) Clean the pig tail
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______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department BTM A B C G
Section Mechanical - - - 1 F+ 1 H
Work Centre TFO - - - 1 F+ 1 H
PF PH PF PH
Monthly
workload(Hours)
Time
(in Hours)
Proposed
Manpower
Activity Description
Crew
Category
WLS No:BSM/W/12
WORK LOAD DETAILS SHEET
Shifts
Present
Manpower
S.
No
Frequency/
Month
No of
Machine
e) Set the Pigtail
f) Cheek &set the alignment from spindle to Pigtail
g) Remove the line dori
d) Start the machine
12 Attend Developmental machine 1 1 1 6 1 6.00 6.00
13 Attend Idle Spindle at the shift starting 26 1 0 2 1 52.00 0.00
14 Count Change in TFO (during General Shift) 1 1 1 0.5 1 0.50 0.50
15
Repair & rectify the parts removed from the
machine (in the room)
1 1 1 6 1 6.00 6.00
A 147.03 95.03
B 166.40 166.40
C 88.4% 57.1%
D 1 1
E 88.4% 57.1%
Total Workload per month ( in man hours )
Net Available man-hours per month(8*26*80% = 166.4 hours)
Present Utilisation(%)
Proposed Manpower
Proposed Utilisation(%)
Total Number of machine: VJ-38 Nos, PRN-10 Nos
_________________________________________________________________________________________________________________________
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___________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
4.0 B BTM SPINNING - ELECTRICAL
MAINTENANCE
________________________________________________________________________________
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_________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
4.0 B
4.1
I II III G T I II III G T
1 Shift maintenance Shift Electrician 1 1 1 - 3 1 1 1 - 3
2 General shift maintenance Gen. Electrician - - - 2 2 - - - 2 2
3 Shift maintenance - Electronics Electronic 1 1 1 - 3 1 1 1 - 3
4 Humidity plant Humidity Attendant 1 1 1 - 3 1 1 1 - 3
5 General shift maintenance Gen.Fitter - - - 3 3 - - - 3 3
6 General shift maintenance Helper - - - 1 1 - - - 1 1
7 Motor maintenance Motor Winder - - - 1 1 - - - 1 1
8 Over head blower maintenance OHB Fitter - - - 1 1 - - - 1 1
9 Gutter cleaning Gutter Cleaner - - - 3 3 - - - 3 3
10 Motor maintenance Motor Fitter - - - 1 1 - - - 1 1
3 3 3 12 21 3 3 3 12 21
BTM SPINNING - ELECTRICAL MAINTENANCE
Manpower Deployment
S. No Section / Work area Designation
Present Manpower Proposed Manpower
Remarks
Total
___________________________________________________________________________________________________________________
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___________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
4.0 B
4.2
1
BTM SPINNING - ELECTRICAL MAINTENANCE
Proposed Changes & Observations
No changes proposed.
________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
5 A FIBER DYEING
________________________________________________________________________________________
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___________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
5.0 A
5.1
I II III G T I II III G T
1 HTHP Dyeing M/c -1 Operator 1 1 1 - 3
2 HTHP Dyeing M/c -2 Operator 1 1 1 - 3
3 HTHP Dyeing M/c -3 Operator 1 1 1 - 3
4 HTHP Dyeing M/c -4 Operator 1 1 1 - 3
5
25 kg Sample dyeing m/c
(HTHP-5)
Operator 1 1 1 - 3
6
Stemping & Hydroextractor
M/C -120 & 280 Kg
Helper 3 3 3 - 9
7
Stemping & Hydroextractor
M/C-320 Kg
Helper 1 1 1 - 3
8
Stemping & Hydroextractor
M/C-700 Kg
Helper 2 2 2 - 6
9
Radio Frequency
dryer/Steam Dryer
Operator 4 4 4 - 12 3 3 3 - 9
10 Store Man Store person 1 1 1 - 3 1 1 1 - 3
11 Yarn Preperation Operator 1 1 - - 2 1 1 - - 2
12 SSM Winding M/c Winder 1 1 1 - 3 1 1 1 - 3
13 Floor Cleaner Cleaner - - - 1 1 - - - 1 1
14 SAP Data Entry operator - - - 1 1 - - - 1 1
15 Maintenance Fitter/Helper - - 1 2 3 - - 1 2 3
18 18 18 4 58 14 14 14 4 46
S. No Section / Work area Designation
Present Manpower Proposed Manpower
5 5
FIBER DYEING
Manpower Deployment
- 5
Remarks
Total
15
3 3 3 - 9
_________________________________________________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
5.0 A
5.2
5.2.1
I
II
III
Deploy three personnel per shift for radio frequency drier instead of present four
personnel per shift.
The utilisation of individual batch of operator are less, mainly because of HTHP
dyeing cycle time constraint.
Hence, it is recommended to form a pool of workers to minimize the forced idleness.
Based on the workload analysis, It is recommended to deploy five personnel for
above machines and their combined utilisation would be 82.66%
The present manpower deployment in the Stemping and Hydroextractor are as
follows:
Manual Stemping & Hydro (120 Kg & 280 Kg ) - 3 person/shift
HTHP Dyeing Machine Operator:
Radio Frequency Drier
Machine Stemping (700 kg) - 2 person/shift
Machine Stemping (320 kg) - 1 person/shift
FIBER DYEING
Proposed Changes & Observations
Proposed Changes
In view of low utilisation of HTHP dyeing machine operator, it is recommended to
provide a group of three people for five(HTHP-1,2,3 4&5) machines. They relieve
each other for lunch, tea and personal needs.
Stemping & Hydroextractor:
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
5.0 A
5.3
S.No Area of work
1 HTHP Dyeing M/c -1
2 HTHP Dyeing M/c -2,3 & 4
3
25 Kg Sample HTHP Dyeing M/c -
5
4
Stemping & Hydroextractor M/C-
120 & 280 Kg
5
Stemping & Hydroextractor M/C-
320 Kg
6
Stemping & Hydroextractor M/C-
700 Kg
7
Propsoed Workload for Stemping
&hydroextractor
8
Radio Frequency dryer/Steam
Dryer -Polyester Batch
9
Radio Frequency dryer/Steam
Dryer -Viscose Batch
10 Store Man
11 Yarn Preperation
12 SSM Winding M/c
13 Floor Cleaner
14
Sap Data Entry operator
15 Maintenance FD/MAINT/01
FD/W/03
FD/W/05
FD/W/12
FD/W/13
FD/W/11
FD/W/08
FD/W/09
FIBER DYEING
Workload Sheets Summary
WLS Number
FD/W/01
FD/W/10
FD/W/04
FD/W/06
FD/W/07
FD/W/08 A
FD/W/02
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 1 1 1 -
Designation Proposed Manpower 1 1 1 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
1 5 1.50 7.50
2
1 5 2.52 12.60
3
1 5 4.00 20.00
4
1 5 0.20 1.00
5
1 5 2.66 13.30
6
1 5 1.76 8.80
7
1 5 1.38 6.90
8
1 5 1.42 7.10
9
1 5 2.12 10.60
10
1 5 0.18 0.90
11
1 5 1.95 9.76
12 1 5 0.58 2.90
13
1 5 3.42 17.10
14 1 5 3.00 15.00
A 133.46
B 12
C 149.47
D 450
E 33.22%
F 1
G 33.22%
WLS No: FD/W/01
WORK LOAD DETAILS SHEET
Fibre Dyeing
Shifts A B C G
HTHP- M/C 1
Take color & chemical according to drug slip from the
store
Mix colors in the addition tank, manually open/close the
water lines and mix
Transfer to main vessel
HTHP Machine-100 Kg
Operator
Activity Description
Check Drugs Slips and intructutions of supervisor before
start new lot
Take fresh water and mix liquid chemicals and transfer to
main vessel
Take fresh water and again mix chemical and transfer to
main vessel
Collect sample to check pH, show to supervisor
Fill the log book
Drain water from the main vessel, Mix chemicals in main
vessel and switch off once water level reaches
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Drain the solution from main vessel, open the lid
Take crane, lift the carrier and keep it on the ground
Write in the log book
Drain water from sample port, collect sample fibre from
port, dry the fibre and make sample
Show to supervisor for approval
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Remarks:
As this machine is semi automatic and two level system, the activities required operators
involvement is more than the remaining ( HTHP-2,3 & 4) machines.
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre
Present
Manpower
3 3 -
Designation
Proposed
Manpower
1 1 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Allow
ance
(%)
Total
Time
(mins)
1
1 1 0.84 12 0.94
2
1 1 0.87 12 0.97
3
1 1 0.22 12 0.25
4
1 1 7.08 12 7.93
5
1 1 0.94 12 1.05
6
1 1 0.67 12 0.75
7
1 1 0.80 12 0.90
8
1 1 1.20 12 1.34
9
1 1 1.37 12 1.53
10
1 1 2.33 12 2.61
11 1 1 3.00 12 3.36
12 1 5 2.00 12 11.20
13
1 1 1.50 12 1.68
14
1 1 2.52 12 2.82
WLS No: FD/W/02
WORK LOAD DETAILS SHEET
Fibre Dyeing
Shifts A
Activity Description
HTHP-2,3 & 4
B
Remove the hook, close the lid of the main vessel
HTHP operator attends more than one machine(in the proposed method). As the operator is
responsible for the operation of more than one machine,if two machines requires operators
attention simultaneously,one of them must wait until he completes his work on the other.
This time loss representing waiting time due to overlapping of machine stoppage is called
"Interference loss".
Thomas O Connor table is used for estimating this interference loss in the textile mills.
C G
Lift the carrier from ground and keep inside the
main vessel
Collect sample fibre from sample port(at the end
holding time-10 mins prior) , dry and make
sample
HTHP Machine
Operator
Check Drugs Slips and intructutions of supervisor
before start new lot
Add chemicals and colors based on the
programme in the main vessel & wait to mix
properly and maintain the water level
Note down the details in the log book
Take color & chemical according to drug slip
from the store
Handover to supervisor for checking/verification
3
1
Open the HTHP vessel, put hook, take crane and
join the hook(carrier) with the crane
Lift the carrier and place it on the ground
Note down the parameters in the logbook
Collect solution from sample port for pH
checking, Show to supervisor
Remove the crane joint, Put on the loaded carrier
Open the stock tank water and close and operation
in the panel board
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre
Present
Manpower
3 3 -
Designation
Proposed
Manpower
1 1 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Allow
ance
(%)
Total
Time
(mins)
WLS No: FD/W/02
WORK LOAD DETAILS SHEET
Fibre Dyeing
Shifts A
Activity Description
HTHP-2,3 & 4
B C G
HTHP Machine
Operator
3
1
15
1 1 2.20 12 2.46
A 39.80
B 9
C 358.24
D 1440
E 24.88%
F 1
G 65.34%
Basic Workload per Shift ( in man minutes)
Total Workload ( in man minutes )
Remarks:
Proposed Utilisation(%) From O'Conner Table
Total Cycle time - 147+11.42 = 158.42 mins
The lowest cycle time shade is selected, because the requirement operator involvement is more in
the smallest cycle. When one operator handles more than one machine, then the activities become
random in nature and interference comes into the picture. Hence , we have used the interference
table to arrive the number of machine one operator can handle.
Light & Medium Shade -Polyester batch ( Standard cycle time collected from company)
Proposed Manpower per shift
Activity sequence depends only on the Shade of batch is processing whether
Light,Medium,dark,heavy dark and special shade.
The activities performed by the operators(HTHP-2,3&4) are same in nature.
No of batches( 3 batch per operator*3 operators=9 batch per shift)
t2 (Average time in min taken by operator per mrh to perform non-deferrable work while m/c is
running) = 27.01 mins(Sum of S.No 8 to 15)
From Thomas O'Conner table ,
Remove the fibre of last batch from sample port
and put new batch fibre in the port
Net Available man-mins(480*3 =1440 mins)
Machine Efficiency, E = 80.44 %
Operator workload,B, as a fraction of a clock hour = 0.6534
Machine Cycle time - 147 mins
Loading/unloading Time - 11.42 mins
t (Average time in min taken by operator per mrh to perform non-deferrable work with the machine
stopped) = 12.79 mins (Sum of S.No 1 to 7)
Present Utilisation(%)
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 1 1 1 -
Designation Proposed Manpower 1 1 1 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
1 2 1.05 2.10
2
1 2 1.62 3.24
3
1 2 2.17 4.34
4
1 2 1.23 2.46
5
1 2 1.37 2.74
6
1 2 1.23 2.46
7 1 2 1.10 2.20
8
1 2 2.55 5.10
9
1 2 3.14 6.28
10
1 2 0.26 0.52
11
1 2 0.40 0.80
12 1 2 1.47 2.94
13
1 2 0.57 1.14
14
1 2 2.02 4.05
15
1 2 0.84 1.68
16
1 2 5.46 10.92
17 1 2 1.32 2.64
18 1 2 0.41 0.82
19 1 2 1.01 2.02
20
1 2 0.50 1.00
21
1 2 3.00 6.00
22 1 2 1.05 2.10
WLS No: FD/W/03
WORK LOAD DETAILS SHEET
Fibre Dyeing
Shifts A B C G
HTHP - No 5
Take crane,Lift the carrier from the vessel and keep it on
the ground
Come down,keep the empty chemcial can,discuss with
the supervisor regrding the next batch,get programme
slip
Take small trolley,move near to the carrier
HTHP Machine-25 Kg
Operator
Activity Description
Open the sample port cover,main vessel cover and switch
on
Remove the lid cover,open the lid cloth
Remove the bale from the carrier and keep it on the
trolley
Move near the hydroextractor-1
Place the plate inside the hydroextractor and lift the bale
and put it on the hydroextractor
Push the bales evenly and close with the cloth and close
the hydro with the lid
Close the locks of the hydroextractor
Keep the lid in place and trolley aside
Take empty bag,weigh 25 kg of fibre
Move the fibre near to the carrier
Take the cloth from the table and spread around the
carrier
Take the carrier plate and keep inside the carrier& wet
the cloth
Load the bale inside the carrier and spray the water &
press manually
Close the cloth & tie
Keep the lid tightener and tight
Throw bale cover outside and clean the area
Take the chemicals and colors from stores,come near to
the machine
Take the water in main vessel by switch on/off(open
valves)
Mix chemcials in the main vessel
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 1 1 1 -
Designation Proposed Manpower 1 1 1 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
WLS No: FD/W/03
WORK LOAD DETAILS SHEET
Fibre Dyeing
Shifts A B C G
HTHP - No 5
HTHP Machine-25 Kg
Operator
Activity Description
23
1 2 1.41 2.82
24
1 2 0.56 1.12
25 1 2 1.02 2.04
26
1 2 1.44 2.88
27
1 2 0.20 0.40
28
1 2 0.40 0.80
29 1 2 2.00 4.00
30
72.00
31
1 2 3.25 6.50
32
1 2 2.40 4.80
33 1 2 4.00 8.00
34
2.00
35
1 2 2.04 4.08
36 1 2 5.06 10.12
37 1 2 2.32 4.64
38
1 2 2.30 4.60
39
1 2 5.00 10.00
40 1 2 5.00 10.00
41 1 2 0.48 0.96
42
1 2 1.00 2.00
43
1 2 1.13 2.26
A 149.57
B 13
C 169.01
D 450
E 37.56%
F 1
G 37.56%
Mix the acid solution to the main vessel
Unoccupied time(waiting for holding time to complete)
Take the water in the additional tank manually operating
and mix the acetic acid
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Waiting for the mixing to be proper and operations in the
panel board
Lift the loaded carrier using crane from the ground and
keep inside the main vessel
Basic Workload per Shift ( in man minutes)
After holding time,drain the finish solution and close the
valve&operation in control panel
Transfer the solution to main vessel
Put the finsih solution in additional tank
Fill the log book
Hot wash drain
Cold wash drain
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Drain hot water
Remove steam,collect sample from sample port and
close
Dry the sample by keeping on the top of HTHp main
vessel & prepare sample
Remove the OH crane,tighten the lid
Increase the water level by operating valves manually
Close the lid of the main vessel
Open & close the valve of the port and maintain water
level
Fill the log book
Machine Cycle time(For Light & medium shade)10
mins prior to the end of holding time
Show the sample to the supervisor and discussion
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 1 1 1 -
Designation Proposed Manpower 1 1 1 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
WLS No: FD/W/03
WORK LOAD DETAILS SHEET
Fibre Dyeing
Shifts A B C G
HTHP - No 5
HTHP Machine-25 Kg
Operator
Activity Description
The machine cycle time(heating,cooling) where the physical involvement of the worker is not
considered.
The HTHP-5 (25 kg smaple machine) will be operational,only when the programme is scheduled by
PPC.
The above incumbent performs the above activity when there is a scheduled planning. The
remaining time,the incumbent acts as a reliver for HTHP-1,23, & 4 operators.
Remarks:
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 3 3 3 -
Designation Proposed Manpower -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
A
1
2 5 3.00 30.00
2
1 5 1.00 5.00
3
1 5 3.72 18.60
4 1 5 2.28 11.40
5
2 5 6.00 60.00
6 2 5 2.75 27.50
7 2 5 3.05 30.50
8
2 5 4.30 43.00
9
1 5 5.00 25.00
B
1
1 10 2.68 26.80
2 1 10 2.14 21.40
3
1 10 3.80 38.00
4
1 0.00
5 1 10 1.52 15.20
6
1 10 2.00 20.00
7
2 10 2.00 40.00
8
1 10 3.00 30.00
9 1 1 2.10 2.10
10
2 1 11.00 22.00
11
1 1 4.00 4.00
WLS NO: FD/W/04
WORK LOAD DETAILS SHEET
Fibre Dyeing
Shifts A B C G
Hydroextractor & Stemping
Fibre denier and bale number write down into program
register in Front of lot no.
Stemping 120 Kg& 280 Kg
Clean the filter cloth and set into dyeing carrier as per shade
color (dark or light)
Place the bottom Carrier plate inside the carrier
Helper
Activity Description
Stemping - 120 Kg Batch - Manual Stemping
See the Noted prog. from prog. register and take instructions
from supervisor to fill fibre in dyeing carrier ,Bring the fibre
and Weight according to program (check denier and bale
number)
Fill the fiber after hand open as per the programme( 1 person
manually stemping) & wet fibre properly during filling
After half loading of bale, put a plate into carrier
Fill the 2nd half of bale into the carrier
After bale loading, close the lid and filter cloth tightly
After complete the filling work clean batching area and
preparation for next lot
Hydro extractor
After receiving the dyed fibre carrier- open the lid ,Change
the hanging from old one to new carrier
Open the filter cloth
Take out the first plate of fibre cake and fill into hydro
extractor, close the lid and lock of hydro
Run the hydro according to type of fibre and instructions of
supervisor ( Machine Cycle time)( Parallel operator performs
other activity)
Bring the empty trolley
After completetion of hydro (stop the M/C) open lock , lid
and take out the extracted fibre cake
Move the trolley with fibre & paste the slip of information
about lot and keep aside
Clean hydro extracting area with water and broom stick
Clean the Carrier plates with chemical cloth and water
Clean the carrier drum with chemical dipped cloth and water
Clean the carrier lid with chemical dipped cloth and water
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 3 3 3 -
Designation Proposed Manpower -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
WLS NO: FD/W/04
WORK LOAD DETAILS SHEET
Fibre Dyeing
Shifts A B C G
Hydroextractor & Stemping
Stemping 120 Kg& 280 Kg
Helper
Activity Description
12 1 1 10.00 10.00
C
1
2 3 4.81 28.86
2
1 3 1.00 3.00
3
1 3 4.41 13.23
4 1 3 2.28 6.84
5
2 3 7.21 43.26
6 2 3 1.73 10.38
7
2 3 5.37 32.22
8
2 3 3.63 21.75
9
1 3 10.00 30.00
D
1
1 6 2.68 16.08
2 1 6 2.14 12.84
3
1 6 4.00 24.00
4
1 6
5 1 6 1.52 9.12
6
1 6 4.03 24.18
7
2 6 2.00 24.00
8
1 6 3.00 18.00
9 1 1 2.10 2.10
10
2 1 11.00 22.00
Dry the cloth by putting in the Hydroextractor
Stemping -280 Kg Batch - Manual Stemping
See the Noted prog. from prog. register and take instructions
from supervisor to fill fibre in dyeing carrier ,Bring the fibre
and Weight according to program (check denier and bale
number)
Fibre denier and bale number write down into program
register in Front of lot no.
Clean the filter cloth and set into dyeing carrier as per shade
color (dark or light)
Place the bottom Carrier plate inside the carrier
Fill the fiber after hand open as per the programme & wet
fibre properly during filling (Manual Stemping)
After loading half carrier, put a plate into carrier
Fill the fiber after hand open as per the programme & wet
fibre properly during filling (Manual Stemping)
After full loading, close the lid and filter cloth tightly.
After complete the filling work clean batching area and
prepration for next lot
Hydro extractor
After receiving the dyed fibre carrier open the lid, Change the
hanging from old one to new carrier
Open the filter cloth
Take out the first plate of fibre cake and fill into hydro
extractor, close the lid and lock of hydro
Run the hydro according to type of fibre and instructions of
supervisor ( Machine Cycle time)( Parallel operator performs
other activity)
Bring the empty trolley
After completetion of hydro (stop the M/C) open lock and lid
and take out the extracted fibre cake into trolley
Move the trolley with fibre & paste the slip of information
about lot and keep aside
Clean hydro extracting area with water and broom stick
Clean the Carrier plates with chemical cloth and water
Clean the carrier drum with chemical dipped cloth and water
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 3 3 3 -
Designation Proposed Manpower -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
WLS NO: FD/W/04
WORK LOAD DETAILS SHEET
Fibre Dyeing
Shifts A B C G
Hydroextractor & Stemping
Stemping 120 Kg& 280 Kg
Helper
Activity Description
11
1 1 4.00 4.00
12 1 1 10.00 10.00
A 836.36
B 14
C 953.45
D 450
E 70.63%
Dry the cloth by putting in the Hydroextractor
Clean the carrier lid with chemical dipped cloth and water
Remarks:
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 1 1 1 -
Designation Proposed Manpower - - - -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
A
1
2 3 4.81 28.86
2
1 3 1.00 3.00
3
1 3 4.41 13.23
4
1 3 2.28 6.84
5
1 3 5.13 15.39
6 1 3 2.32 6.96
7
1 3 6.34 19.02
8
1 3 3.63 10.88
9
1 3 10.00 30.00
B 0.00
1
1 6 2.14 12.84
2 1 6 2.14 12.84
3
1 6 3.56 21.36
4
5 1 6 1.52 9.12
6
1 6 4.03 24.18
7
2 6 2.00 24.00
8
1 6 3.00 18.00
Open the filter cloth
Move the trolley with fibre & paste the slip of
information about lot and keep aside
Bring the empty trolley
Run the hydro according to type of fibre and instructions
of supervisor ( Machine Cycle time)( Paralley operator
performs other activity)
After completetion of hydro (stop the M/C) open lock and
lid and take out the extracted fibre cake into trolley
Clean hydro extracting area with water and broom stick
Take out the first plate of fibre cake and fill into hydro
extractor,close the lid and lock of hydro
Place the bottom Carrier plate inside the carrier,Turn the
stemping machine & start
Fill the fiber after hand open as per the programme & wet
fibre properly during filling (Machine Stemping)
After loading half carrier, put a plate into carrier
Fill the fiber after hand open as per the programme & wet
fibre properly during filling (Machine Stemping)
After full loading, close the lid and filter cloth tightly.
After complete the filling work clean batching area and
prepration for next lot
Stemping 320 kg
Hydroextractor&Stemping
Hydro extractor
After receiving the dyed fibre carrier open the lid and
filter cloth,Change the hanging from old one to new
carrier
Helper
Activity Description
See the Noted prog. from prog. register and take
instructions from supervisor to fill fibre in dyeing carrier
,Bring the fibre and Weight according to program (check
denier and bale number)
Fibre denier and bale number write down into program
register in Front of lot no.
Clean the filter cloth and set into dyeing carrier as per
shade color (dark or light)
Stemping - 320 Kg Batch - Mechanical Stemping
WLS No: FD/W/05
WORK LOAD DETAILS SHEET
Fibre Dyeing
Shifts A B C G
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 1 1 1 -
Designation Proposed Manpower - - - -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
Stemping 320 kg
Hydroextractor&Stemping
Helper
Activity Description
WLS No: FD/W/05
WORK LOAD DETAILS SHEET
Fibre Dyeing
Shifts A B C G
9 1 1 2.10 2.10
10
2 1 11.00 22.00
11
1 1 4.00 4.00
12 1 1 10.00 10.00
A 160.44
B 13
C 181.30
D 450
E 40.29%
Remarks:
Clean the Carrier plates with chemcial cloth and water
Basic Workload per Shift ( in man minutes)
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Rest & Relaxation Allowances ( % )
Clean the carrier lid with chemcial dipped cloth and water
Clean the carrier drum with chemcial dipped cloth and
water
Dry the cloth by putting in the hydroextractor
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 2 2 2 -
Designation Proposed Manpower - - -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
A
1
2 3 5.84 35.01
2
2 3 1.00 6.00
3
2 3 7.00 42.00
4
2 3 4.18 25.08
5
2 3 7.50 45.00
6 2 3 2.01 12.06
7
2 3 10.15 60.90
8
2 3 3.01 18.06
9
2 3 5.00 30.00
B 0.00
1
2 6 2.68 32.16
2 1 6 2.14 12.84
3
1 6 3.56 21.36
4
6 0.00
5 1 6 1.52 9.12
6
2 6 5.15 61.80
7
2 6 2.00 24.00
8
1 6 3.00 18.00
9 1 1 2.10 2.10
Clean hydro extracting area with water and broom stick
Clean the Carrier plates with chemical cloth and water
After loading half carrier, put a plate into carrier
Fill the fiber after hand open as per the programme & wet
fibre properly during filling (Machine Stemping)
After full loading, close the lid and filter cloth tightly.
After complete the filling work clean batching area and
prepration for next lot
Move the trolley with fibre & paste the slip of
information about lot and keep aside
Run the hydro according to type of fibre and instructions
of supervisor ( Machine Cycle time)( Parallel operator
performs other activity)
See the Noted prog. from prog. register and take
instructions from supervisor to fill fibre in dyeing carrier
,Bring the fibre and Weight according to program (check
denier and bale number)
Fibre denier and bale number write down into program
register in Front of lot no.
Clean the filter cloth and set into dyeing carrier as per
shade color (dark or light)
Fill the fiber after hand open as per the programme & wet
fibre properly during filling (Machine Stemping)
After completetion of hydro (stop the M/C) open lock and
lid and take out the extracted fibre cake & put in the
trolley
WLS No: FD/W/06
WORK LOAD DETAILS SHEET
Fibre Dyeing
Shifts A B C
Hydroextractor&Stemping
G
Helper
Open the filter cloth
Bring the empty trolley
Activity Description
Stemping - 700 Kg Batch - Mechanical Stemping
Stemping 700Kg
Place the bottom Carrier plate inside the carrier, Turn the
stemping machine & start
Hydro extractor
After receiving the dyed fibre carrier open the lid ,Change
the hanging from old one to new carrier
Take out the first plate of fibre cake and fill into hydro
extractor, close the lid and lock of hydro
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 2 2 2 -
Designation Proposed Manpower - - -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
WLS No: FD/W/06
WORK LOAD DETAILS SHEET
Fibre Dyeing
Shifts A B C
Hydroextractor&Stemping
G
Helper
Activity Description
Stemping 700Kg
10
2 1 15.00 30.00
11
1 1 5.00 5.00
12 1 1 10.00 10.00
A 226.38
B 13
C 255.81
D 450
E 28.42%
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Remarks:
Clean the carrier lid with chemical dipped cloth and water
Dry the cloth by putting in the hydroextractor
Clean the carrier drum with chemical dipped cloth and
water
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 6 6 6 -
Designation Proposed Manpower 5 5 5 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
A
1
2 5 3.00 30.00
2
1 5 1.00 5.00
3
1 5 3.72 18.60
4 1 5 2.28 11.40
5
2 5 6.00 60.00
6 2 5 2.75 27.50
7 2 5 3.05 30.50
8
2 5 4.30 43.00
9
1 5 5.00 25.00
B
1
1 10 2.68 26.80
2 1 10 2.14 21.40
3
1 10 3.80 38.00
4
1 0.00
5 1 10 1.52 15.20
6
1 10 2.00 20.00
7
2 10 2.00 40.00
8
1 10 3.00 30.00
9 1 1 2.10 2.10
Run the hydro according to type of fibre and instructions of
supervisor ( Machine Cycle time)( Parallel operator
performs other activity)
Clean the filter cloth and set into dyeing carrier as per shade
color (dark or light)
Place the bottom Carrier plate inside the carrier
Fill the fiber after hand open as per the programme( 1
person manually stemping) & wet fibre properly during
filling
After half loading of bale, put a plate into carrier
Fill the 2nd half of bale into the carrier
After bale loading, close the lid and filter cloth tightly
Bring the empty trolley
Take out the first plate of fibre cake and fill into hydro
extractor, close the lid and lock of hydro
Stemping - 120 Kg Batch - Manual Stemping
B C
After completetion of hydro (stop the M/C) open lock , lid
and take out the extracted fibre cake
Move the trolley with fibre & paste the slip of information
about lot and keep aside
Clean hydro extracting area with water and broom stick
Clean the Carrier plates with chemical cloth and water
WLS NO: FD/W/07
WORK LOAD DETAILS SHEET
Fibre Dyeing
Shifts A G
Open the filter cloth
FD
See the Noted prog. from prog. register and take
instructions from supervisor to fill fibre in dyeing carrier
,Bring the fibre and Weight according to program (check
denier and bale number)
Fibre denier and bale number write down into program
register in Front of lot no.
Hydro extractor
After receiving the dyed fibre carrier- open the lid ,Change
the hanging from old one to new carrier
Hydroextractor &
Stemping
Helper
Activity Description
After complete the filling work clean batching area and
prepration for next lot
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 6 6 6 -
Designation Proposed Manpower 5 5 5 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
B C
WLS NO: FD/W/07
WORK LOAD DETAILS SHEET
Fibre Dyeing
Shifts A G
FD
Hydroextractor &
Stemping
Helper
Activity Description
10
2 1 11.00 22.00
11
1 1 4.00 4.00
12 1 1 10.00 10.00
C
1
2 3 4.81 28.86
2
1 3 1.00 3.00
3
1 3 4.41 13.23
4 1 3 2.28 6.84
5
2 3 7.21 43.26
6 2 3 1.73 10.38
7
2 3 5.37 32.22
8
2 3 3.63 21.75
9
1 3 10.00 30.00
D
1
1 6 2.68 16.08
2 1 6 2.14 12.84
3
1 6 4.00 24.00
4
1 6
5 1 6 1.52 9.12
6
1 6 4.03 24.18
Fill the fiber after hand open as per the programme & wet
fibre properly during filling (Manual Stemping)
Take out the first plate of fibre cake and fill into hydro
extractor, close the lid and lock of hydro
Run the hydro according to type of fibre and instructions of
supervisor ( Machine Cycle time)( Parallel operator
performs other activity)
Bring the empty trolley
After completetion of hydro (stop the M/C) open lock and
lid and take out the extracted fibre cake into trolley
Clean the filter cloth and set into dyeing carrier as per shade
color (dark or light)
Place the bottom Carrier plate inside the carrier
Fill the fiber after hand open as per the programme & wet
fibre properly during filling (Manual Stemping)
After loading half carrier, put a plate into carrier
Dry the cloth by putting in the hydroextractor
After full loading, close the lid and filter cloth tightly.
After complete the filling work clean batching area and
prepration for next lot
Hydro extractor
After receiving the dyed fibre carrier open the lid, Change
the hanging from old one to new carrier
Open the filter cloth
Fibre denier and bale number write down into program
register in Front of lot no.
See the Noted prog. from prog. register and take
instructions from supervisor to fill fibre in dyeing carrier
,Bring the fibre and Weight according to program (check
denier and bale number)
Stemping -280 Kg Batch - Manual Stemping
Clean the carrier drum with chemical dipped cloth and
water
Clean the carrier lid with chemical dipped cloth and water
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 6 6 6 -
Designation Proposed Manpower 5 5 5 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
B C
WLS NO: FD/W/07
WORK LOAD DETAILS SHEET
Fibre Dyeing
Shifts A G
FD
Hydroextractor &
Stemping
Helper
Activity Description
7
2 6 2.00 24.00
8
1 6 3.00 18.00
9 1 1 2.10 2.10
10
2 1 11.00 22.00
11
1 1 4.00 4.00
12 1 1 10.00 10.00
E
1
2 3 4.81 28.86
2
1 3 1.00 3.00
3
1 3 4.41 13.23
4
1 3 2.28 6.84
5
1 3 5.13 15.39
6 1 3 2.32 6.96
7
1 3 6.34 19.02
8
1 3 3.63 10.88
9
1 3 10.00 30.00
F
1
1 6 2.14 12.84
2 1 6 2.14 12.84
3
1 6 3.56 21.36
Take out the first plate of fibre cake and fill into hydro
extractor, close the lid and lock of hydro
Fibre denier and bale number write down into program
register in Front of lot no.
Clean the filter cloth and set into dyeing carrier as per shade
color (dark or light)
Place the bottom Carrier plate inside the carrier, Turn the
stemping machine & start
Fill the fiber after hand open as per the programme & wet
fibre properly during filling (Machine Stemping)
After loading half carrier, put a plate into carrier
Fill the fiber after hand open as per the programme & wet
fibre properly during filling (Machine Stemping)
After full loading, close the lid and filter cloth tightly.
After complete the filling work clean batching area and
prepration for next lot
Hydro extractor
Clean the carrier drum with chemical dipped cloth and
water
Clean the carrier lid with chemical dipped cloth and water
Dry the cloth by putting in the hydroextractor
Open the filter cloth
After receiving the dyed fibre carrier open the lid and filter
cloth, Change the hanging from old one to new carrier
Stemping - 320 Kg Batch - Mechanical Stemping
See the Noted prog. from prog. register and take
instructions from supervisor to fill fibre in dyeing carrier
,Bring the fibre and Weight according to program (check
denier and bale number)
Move the trolley with fibre & paste the slip of information
about lot and keep aside
Clean hydro extracting area with water and broom stick
Clean the Carrier plates with chemical cloth and water
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 6 6 6 -
Designation Proposed Manpower 5 5 5 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
B C
WLS NO: FD/W/07
WORK LOAD DETAILS SHEET
Fibre Dyeing
Shifts A G
FD
Hydroextractor &
Stemping
Helper
Activity Description
4
5 1 6 1.52 9.12
6
1 6 4.03 24.18
7
2 6 2.00 24.00
8
1 6 3.00 18.00
9 1 1 2.10 2.10
10
2 1 11.00 22.00
11
1 1 4.00 4.00
12 1 1 10.00 10.00
G 0.00
1
2 3 5.84 35.01
2
2 3 1.00 6.00
3
2 3 7.00 42.00
4
2 3 4.18 25.08
5
2 3 7.50 45.00
6 2 3 2.01 12.06
7
2 3 10.15 60.90
8
2 3 3.01 18.06
9
2 3 5.00 30.00
Dry the cloth by putting in the hydroextractor
Stemping - 700 Kg Batch - Mechanical Stemping
See the Noted prog. from prog. register and take
instructions from supervisor to fill fibre in dyeing carrier
,Bring the fibre and Weight according to program (check
denier and bale number)
Fibre denier and bale number write down into program
register in Front of lot no.
Clean the filter cloth and set into dyeing carrier as per shade
color (dark or light)
Place the bottom Carrier plate inside the carrier, Turn the
stemping machine & start
Fill the fiber after hand open as per the programme & wet
fibre properly during filling (Machine Stemping)
After loading half carrier, put a plate into carrier
Fill the fiber after hand open as per the programme & wet
fibre properly during filling (Machine Stemping)
After full loading, close the lid and filter cloth tightly.
After complete the filling work clean batching area and
prepration for next lot
Run the hydro according to type of fibre and instructions of
supervisor ( Machine Cycle time)( Parallel operator
performs other activity)
Bring the empty trolley
After completetion of hydro (stop the M/C) open lock and
lid and take out the extracted fibre cake into trolley
Move the trolley with fibre & paste the slip of information
about lot and keep aside
Clean hydro extracting area with water and broom stick
Clean the Carrier plates with chemical cloth and water
Clean the carrier drum with chemical dipped cloth and
water
Clean the carrier lid with chemical dipped cloth and water
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 6 6 6 -
Designation Proposed Manpower 5 5 5 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
B C
WLS NO: FD/W/07
WORK LOAD DETAILS SHEET
Fibre Dyeing
Shifts A G
FD
Hydroextractor &
Stemping
Helper
Activity Description
H 0.00
1
2 6 2.68 32.16
2 1 6 2.14 12.84
3
1 6 3.56 21.36
4
6 0.00
5 1 6 1.52 9.12
6
2 6 5.15 61.80
7
2 6 2.00 24.00
8
1 6 3.00 18.00
9 1 1 2.10 2.10
10
2 1 15.00 30.00
11
1 1 5.00 5.00
12 1 1 10.00 10.00
A 1631.47
B 14
C 1859.87
D 450
E 68.88%
F 5
G 82.66%
Clean the carrier lid with chemical dipped cloth and water
Dry the cloth by putting in the hydroextractor
Run the hydro according to type of fibre and instructions of
supervisor ( Machine Cycle time)( Parallel operator
performs other activity)
Bring the empty trolley
After completetion of hydro (stop the M/C) open lock and
lid and take out the extracted fibre cake & put in the trolley
Move the trolley with fibre & paste the slip of information
about lot and keep aside
Clean hydro extracting area with water and broom stick
Clean the Carrier plates with chemical cloth and water
After receiving the dyed fibre carrier open the lid ,Change
the hanging from old one to new carrier
Open the filter cloth
Take out the first plate of fibre cake and fill into hydro
extractor, close the lid and lock of hydro
Clean the carrier drum with chemical dipped cloth and
water
Hydro extractor
Proposed Utilisation(%)
Remarks:
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 4 4 4 -
Designation Proposed Manpower 3 3 3 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
A
1
2 15 3.00 90.00
2 2 15 1.10 33.00
3 2 15 0.60 18.00
4
1 15 1.00 15.00
5 1 4400 0.055 242.00
6 198.00
7 1 15 0.91 13.70
8
1 4400 0.06 242.00
9
1 180 0.62 111.60
10
1 15 3.00 45.00
A 810.30
B 14
C 1121.74
D 450
E 62.32%
F 3
G 83.09%
Helper
Activity Description
For polyester batch, the materials are directly fed into R/F drier belt conveyor.
Waiting between the loading(Due to machine speed limit)
For Polyester Fibre in R/F Drier
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes ) ( 923.74+198 = 1121.74 mins)
Net Available man-mins
Take trolley, weigh on weighing balance and write down
on slips gross weight and trolley weight as per priority of
drying based on fibre type co-ordination with supervisor
Move the trolley from weighing machine to R/F drier area
WLS No: FD/W/08
WORK LOAD DETAILS SHEET
Fibre Dyeing
Shifts A
R/F Drier-Polyester
Batch
B C G
Drier
Note: As per discussion with the management personnel, only R/F drier going to be used. So they
workload sheet prepared only for the R/F drier operation.
Proposed Utilisation(%)
Remarks:
Average weight of batch/ trolley - 300 Kg
Target per operator /shift - 1100 Kg * 4 operator = 4400/300 = 15 trolleys (Polyester batch)
Load the Fibre(S.No 5 ) is the actual workload of the operator. Because of belt speed , the operator
has to wait in between loading activity for few seconds/minutes which is called as unavoidable
delay. But operator presence is required. So, the total cycle time = 242 +198 =440 mins/shift. But
Relaxation allowance only provided to activity.
R/F drier capacity(Polyester batch) - 600 kg/hr.
Proposed Manpower per shift
Move the trolley near the R/F drier inlet point
Tie the bag with information card/tag as per lot qty
( 25 kg/ bag = 4400/25=180 Bags)
Move the empty trolley back to respective place
Basic Workload per Shift ( in man minutes)
Present Utilisation(%)
Take instructions from supervisor to dry the lot and set
the speed of conveyer belt according to moisture
Fill fiber in bags after drying (Take the bag, fill &keep
aside)
Load the fibre from trolley to belt conveyor of drier ( kg)
Clean the spillage area around the machine after one
batch dried.
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 3* 3 3 -
Designation Proposed Manpower 2* 2 2 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
2 4 6.10 48.80
2
1 4 0.07 0.28
3
1 4 0.07 0.28
4
1 4 1.95 7.80
5
1 4 1.00 4.00
6 1 1100 0.070 77.00
7 1 363.00
8 1 4 0.91 3.65
9
1 1100 0.06 60.50
10 1 44 0.62 27.28
11
1 4 3.00 12.00
A 547.43
B 14
C 624.07
D 450
E 46.23%
F 2
G 69.34%
Average weight of batch/ trolley - 300 Kg,R/F drier capacity(Viscose batch) - 150 kg/hr.
Target per operate/shift - 1100 Kg for 3 operators = 1100/300 = 4 trolleys (Viscose batch)
Waiting between the loading(Due to machine speed
Move the empty trolley back to respective place
Tie the bag with information card/tag as per lot qty
( 25 kg/ bag = 4400/25=180 Bags)
Net Available man-mins
For Viscose batch, the fibre is first passed through Viscose opener and then fed into belt conveyor.
The moisture content for the viscose batch is in the range of 60-70%
Load the Fibre(S.No 6 ) is the actual workload of the operator. Because of belt speed , the operator
has to wait in between loading activity for few seconds/minutes which is called as unavoidable
delay. But operator presence is required. So, the total cycle time = 77+363=440 mins/shift.
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Remarks:
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Activity Description
Discuss with the shift incharge, weigh the trolley to be
dried and move to R/F drier area
Collect the opened fibre from viscose opener outlet and
keep aside(load it on the R/F drier belt conveyor)
Take instructions from supervisor to dry the lot and set
the speed of conveyer belt according to moisture
Load the fibre from viscose opener outlet to belt
Clean the spillage around the trolley and move the empty
trolley back to Weigh machine area
Viscose Fibre in R/F Drier
Basic Workload per Shift ( in man minutes)
WLS No: FD/W/08 A
WORK LOAD DETAILS SHEET
Fibre Dyeing
Shifts A
Drier
* There is no separate manpower for Viscose batch R/F drier. The above workload sheet is
prepared to show the utilisation of drying operator ,when they perform viscose batch drying.
Viscose Opener
B C G
Tie the bag with information card/tag as per lot qty
Clean the spillage area around the machine after one
batch is over
Open the Viscose fibre and put on the viscose opener
R/F Drier-Viscose Batch
Helper
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 1 1 1 -
Designation Proposed Manpower 1 1 1 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 1 5.00 5.00
2 1 17 3.00 51.00
3 1 17 2.50 42.50
4 1 17 1.00 17.00
5 1 1 3.00 3.00
6
a 1 2 1.51 3.02
b 1 2 3.18 6.36
c 1 2 0.97 1.94
d 1 2 2.73 5.46
e 1 2 1.06 2.12
7 1 1/5 5.00 1.00
8 1 1 30.00 30.00
9 1 1 20.00 20.00
10 1 1/30 420.00 14.00
A 202.40
B 12
C 226.69
D 450
E 50.38%
F 1
G 50.38%
Colour&Chemical Store
Helper
Activity Description
Check stock availability in stock register
WLS No: FD/W/09
WORK LOAD DETAILS SHEET
Fibre Dyeing
Shifts A B C G
Store room
Physical stock verification
Take the empty trolley to store from fibre dyeing
Discussion with the storepersonnel,Load the
materials(Cans,bags,etc) in the trolley as per slip
Tie the thread around the trolley after loading
unload the materials from trolley to storeroom
Weigh the chemicals as per drug slip given by
supervisor(considered 3 chemicals per batch)
Take samples for washing fastness checking to SPH lab
& bring testing report ( Only in A or B Shift)
End of shift note down the color & chemical consumed
in their shift in the register
After completion of work, clean the Colour & Chemical
rooms. Clean the cans surface and chemical spillage
around the cans
Weigh the colors as per drug slip given by
supervisor(considered 3 colours per batch)
After weighing color less that particular dyes and
chemicals in register and upto date the stock
Bring the color & Chemical from store as instructed in
issue slip(Only in A or B shift) **
Net Available man-mins
Total Workload ( in man minutes )
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Remarks:
if any dyes have change the lot no. inform to supervisor
for lab testing and handover samples to the lab
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Move the trolley back to fibre dyeing section store
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 1 1 1 -
Designation Proposed Manpower 1 1 1 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
Colour&Chemical Store
Helper
Activity Description
WLS No: FD/W/09
WORK LOAD DETAILS SHEET
Fibre Dyeing
Shifts A B C G
Store room
Total - 17 batch/shift
** Shifting of colurs & chemicals from stores, floor cleaner in the fibre dyeing dept assist the store
personnel. So crew size for shifting activity is two. Same practice is recommended.
In view of low utilisation of storeman in B shift and C shift (Only 32.32% Activities from 1-
5),personnel is being recommended keeping in mind the follwing: As the operator has to wait every
time for the supervisor before weighinh chemicals and colours,which is impratical. As the
supervisor is already engaged in other activity. The weighment operational is critical and store
personnel is fully responsible.
HTHP 2,3,4 & 5 - 12 batch/shift
HTHP 1- 5 batch /Shift
Number of Batch
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 1 1 - -
Designation Proposed Manpower 1 1 - -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 1 1.07 1.07
2 1 1 5.00 5.00
3 1 1 10.00 10.00
4 1 1 2.83 2.83
5
1 21 1.00 21.00
1 21 0.08 1.68
1 21 0.42 8.82
6
1 21 2.85 59.85
7
1 21 2.91 61.11
1 1 1.67 1.67
1 21 0.60 12.60
1 1 9.50 9.50
1 21 0.56 11.76
1 1 1.77 1.77
8
1 21 1.49 31.29
9
1 21 0.73 15.39
1 1 0.30 0.30
1 1 6.44 6.44
WLS No: FD/W/10
WORK LOAD DETAILS SHEET
Fibre Dyeing
Shifts A B C G
FD
Pilot Plant
Operator
Activity Description
Clean the machine after one shade is over
Breaker & Finisher
Collect the output sliver and cut into pieces
Cheese Winding Machine
Make the cheese cone from the R/F bobbins in the
sample cheese winding machine
Put the carding sliver in machine, pass through the
breaker, collect the breaker sliver output, cut into
pieces again pass through the machine. Collect the
finisher sliver and put it in the cover
Put the finisher silver in the speed frame and make
the s/f roving, Clean the speed frame.
Reach the texmaco ring frame in the unit-2
Insert the rovings in the ring frame and make the
R/F bobbins(2 R/F bobbins per roving)
Machine cycle time
TFO
Take the cheese cone and empty paper cone, reach
the TFO, Put the cones in the respective count
machine
Remove the R/F bobbins from the machine and
clean the machine
Come back to yard development room
Speed frame
Check the machine
Machine cycle time ( In the mean time come to
Yarn developmental room, select the sample card
from the cupboard)
Collect fibre sample from shift incharge and keep
on lab
Keep the sample in the oven
Take the dried sample from oven, put in cover and
write identification slip
Come from fibre dyeing to pilot plant
Carding Machine
Put the samples at the inlet of carding machine
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 1 1 - -
Designation Proposed Manpower 1 1 - -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
WLS No: FD/W/10
WORK LOAD DETAILS SHEET
Fibre Dyeing
Shifts A B C G
FD
Pilot Plant
Operator
Activity Description
1 1 2.16 2.16
10
1 21 1.28 26.88
11 1 21 0.18 3.76
12 1 1 2.83 2.83
13 1 21 0.17 3.65
14
1 21 1.51 31.73
15
1 21 1.26 26.46
A 359.54
B 12
C 402.68
D 450
E 89.48%
F 1
G 89.48%
Come to TFO section and remove the TFO cone
from the machine
Come back to yard development room and put the
cones in the warp machine and make sample yarn (
batch wise)
Clean the R/F bobbins
Come back to fibre dyeing machine
HTHP 1 - 5 batch/shift * 3 Shift = 15 Batch
HTHP 2-4 - 3 batch/shift * 3 Shift * 3 Machine = 27 batch
Total = 42 batch/ day
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
So per shift - 21 batch / shift
Proposed Utilisation(%)
Remarks:
From the past record , 518 batches was prepared in the HTHP and number of tickets made 515
Nos.
The above workload sheet, was calculated
Cut the blue card to prepare ticket
Paste the yarn prepared in the blue card to prepare
the ticket
Check the ticket in the machine, take the printout
and staple the report
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 1 1 1 -
Designation Proposed Manpower 1 1 1 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
1 1 8.00 8.00
2 1 1 53.33 53.33
3
1 1 14.80 14.80
4
1 1 15.83 15.83
5
1 72 138.00 138.00
6
1 1 6.00 6.00
7
1 36 11.88 11.88
8
1 36 11.88 11.88
9
1 1 10.08 10.08
10
1 1 15.00 15.00
11
1 36 4.68 4.68
13
1 1 29.20 29.20
14
1 1 2.40 2.40
15
1 1 6.32 6.32
16 1 1 4.32 4.32
A 331.72
B 13
C 374.85
D 450
E 83.30%
F 1
G 83.30% Proposed Utilisation(%)
Remarks:
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Hand over charge to next shift
Hydro extraction of received dyed filament lot
Rewinding the dyed & grey filament according to
supervisor instruction(72 cones means 6 doffs and the
helper's time attending the m/c is 40% of m/c time for 6
doffs)
During rewind of dyed filament check the conning oil in
every spindle
Check the weight and length of every rewind grey cone
and write into the register and set into rack
Checking every rewind dyed filament cone (shade
varriation and rewinding quality )
Write down the production grey and dyed filament in
production register
Taking cones to SQC for quality checking and write
down sqc register
Put packing slip on each dyed filament cone
Packing the dyed filament cones in cartons with slip(
assuming 1 carton carries 18 cones , so timings are for 5
cartons)
After complete the work of winding clean the winding
area
Check weight of every packed carton and write down on
packing slip
WINDING
Do the cleaning of M/C as per check list
Checking the weight of received grey filament and write
down into grey received register
SSM WINDING
HELPER
Activity Description
Take charge at shift start
WLS No: FD/W/11
WORK LOAD DETAILS SHEET
FIBRE DYEING
Shifts A B C G
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 1
Designation Proposed Manpower - - - 1
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
1 2 91.52 91.52
2 1 100 42.00 42.00
3
1
200
bags
226.00 226.00
4 1 2 18.90 18.90
A 378.42
B 13
C 427.61
D 450
E 95.03%
F 1
G 95.03%
Assist the store man in bringing the required material
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Remarks:
FIBRE DYEING
Cleaning of empty bags
Stitching Of dyed fiber filled bags
FIBRE DYEING
FLOOR CLEANER
Activity Description
Floor cleaning with swab
WLS No: FD/W/12
WORK LOAD DETAILS SHEET
FIBRE DYEING
Shifts A B C G
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - -
Designation Proposed Manpower - - -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
1 1 1 25.00
2 1 1 25.00
3 1 1 20.00
4 1 1 20.00
5 1 11 15.00
6 1 11 15.00
7 1 1 10.00
8 1 11 77.00
9 1 1 5.00
A
B
C
D
E
F
G
Rest & Relaxation Allowances ( % )
Feeding Daily Production in excel
Net Available man-mins
Confirm pending lots in sap
Proposed Utilisation(%)
Remarks:
Maintain dyeing Cards
Make Production Order in sap for dyeing fibre
Basic Workload per Shift ( in man minutes)
B
Total Workload ( in man minutes )
Present Utilisation(%)
Proposed Manpower per shift
Make Card For Dyeing
Daily mail for filament dispatch and transfer it into sap
FIBRE DYEING OFFICE
SAP OPERATOR
Activity Description
C
Match Sap production to actual production
FIBRE DYEING OFFICE
Transfer Daily Fibre to Btm & Elg in sap
Make Ready Daily Advice Slips
WLS No: FD/W/13
WORK LOAD DETAILS SHEET
FIBRE DYEING
Shifts A
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
1
1
Total
Time
(Mins)
25.00
25.00
20.00
20.00
15.00
15.00
10.00
77.00
5.00
212.00
13
239.56
450
53.24%
1
53.24%
Remarks:
G
WLS No: FD/W/13
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - 1 2
Designation Proposed Manpower - - 1 2
Sl.
No
Crew
Size
Total
Time
(man
mins)
1
1.1 2 86.54
1.2 2 44.77
1.3 2 63.46
1.4 2 80.77
1.5 2 112.15
1.6 2 111.35
1.7 2 16.73
1.8 2 48.92
1.9 2 32.77
2 2 36.15
A 633.61
B 15
C 728.65
D 384
E 94.88%
F 2
G 94.88%
1/26
Freq/ Shift
1/26
1/26
1/26
One person in the night shift is provided based on discussion with the incumbent and detailed
discussion with the maintenance personnel. The personnel mainly provided to attend the running
problems occurred in the night shift.It is provided based on the allocation.
1/26
1/26
1/26
1/26
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
SSM Winding Machine - 1 no
Monga Hydro - 1 no
Wet Opener - 2 nos
Remarks:
Hydro Extractor - 5 nos
1/26
HTHP Dyeing Vessel - 5 nos
Electric Hoist - 5 nos
Rest & Relaxation Allowances ( % )
Steam Drier - 2 nos
Net Available man-mins per shift
Total Workload
85 KW RF Drier - 1 no
G
FD&YD
Fitter/Helper
Activity Description
Preventive Maintenance
Stamping Machine - 5 nos
Breakdown
Basic Workload per Shift ( in man minutes)
WLS No: FD/MECH/01
WORK LOAD DETAILS SHEET
Fibre Dyeing
Shifts A B C
Electrical
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
5 B YARN DEVELOPMENT
________________________________________________________________________________________
National Productivity Council, Bangalore.
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___________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
5.0 B
5.1
I II III G T I II III G T
1
3 kg Sample Dyeing M/C &
Fibro Mixer
Helper 1 1 - - 2 1 1 - - 2
2 Beaker Dyeing M/C's Helper 1 1 - - 2 1 1 - - 2
3 Yardage Sample Making
Weaver/sider/
Winder
2 2 2 - 6 2 2 2 - 6
4 Handloom Sample Making
Weaver/winde
r/sider
2 2 - - 4 2 2 - - 4
5 Checker Monitor - - - 1 1 - - - 1 1
6
Dope Dyed & Yarn
Checking
Helper - - - 1 1 - - - 1 1
6 6 2 2 16 6 6 2 2 16 Total
YARN DEVELOPMENT
Manpower Deployment
S. No Section / Work area Designation
Present Manpower Proposed Manpower
Remarks
_________________________________________________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
5.0 B
5.2
1
YARN DEVELOPMENT
Proposed Changes & Observations
No changes proposed.
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
5.0 B
5.2
S.No Area of work
1
3 kg Sample Dyeing M/C & Fibro
Mixer
2 Beaker Dyeing M/C's
3 Yardage Sample Making
4 Checker -Monitor
5 Dope Dyed & Yarn Checking -Helper YD/W/05
YD/W/03 & A
YD/W/04
YARN DEVELOPMENT
Workload Sheets Summary
WLS Number
YD/W/01
YD/W/02
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 1 1 - -
Designation
Proposed
Manpower
1 1 - -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
1 1 15.00 15.00
2
1 3 60.00 60.00
3
1 3 30.00 30.00
A 105.00
B 13
C 118.65
D 450
E 26.37%
F 1
G 26.37%
Proposed Manpower per shift
Proposed Utilisation(%)
Remarks:
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
HTHP DYEING VESSEL
3KG
HELPER-CONTRACT
EMPLOYEE
Activity Description
Take charge of his duty
Weighing grey fibre, dye & chemical as per 3kg dyeing
program
Hyrdro extracting of dyed material to remove excess water
then dry the fibre on RF dryer, put in bags add tags having
info about lot no., shade no., qty. & fineness
WLS No: YD/W/01
WORK LOAD DETAILS SHEET
YDD
Shifts A B C G
YARN DEV. LAB
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 1 1 - -
Designation Proposed Manpower 1 1 - -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 1 10.50 10.50
2
1 2.5 93.75 93.75
3
1 2 90.00 90.00
4 1 1 20.00 20.00
5
1 12.00
6
1 1 15.00 15.00
7
1 1 90.00 90.00
A 331.25
B 13
C 374.31
D 450
E 83.18%
F 1
G 83.18%
**Taking an average of twice in a month
Remarks:
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Bring the dope dyed fibre from godown for mixing
Dyeing 50gm filament yarn sample on multiprecise-TC
sample dyeing m/c **
Weighment of the fibre for 100gm to make yarn sample
cone.
Drying of fibre in hot air oven
Basic Workload per Shift ( in man minutes)
BEAKER DYEING
HELPER(HTHP
DYEING VESSEL
3KG)
Activity Description
Taking charge at the starting of the shift
According to mixing & matching color soln. m pippete
color as per recipes, weighment of fibre & start dyeing.
Open beaker dyeing m/c , drying fibre samples, stick the
fibre sample in record register & mention mixing details
from mixing register.
WLS No: YD/W/02
WORK LOAD DETAILS SHEET
YARN DEV. DEPT.
Shifts A B C G
YARN DEV. LAB
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 1 1 1 -
Designation Proposed Manpower 1 1 1 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
1 1 10.00 10.00
2
1 1 15.00 15.00
3
1 1 10.00 10.00
4
1 1 15.00 15.00
5
1 1 45.00 45.00
7
1 1 30.00 30.00
8
1 1 5.00 5.00
A 130.00
B 13
C 146.90
D 450
E 32.64%
F 1
G 32.64%
Running 15 kgs of lap sample on LR C 1/3 Card
Three passages at drawframe, sliver received from
carding.
Run Drawframe sliver on speed frame to form roving
Remarks:
The above workload is the operator's manual workload. But the operator has to wait during the
machine cycle time.
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
B C
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Take charge of his duty
Running the R/F machine till the doff is due
To give the charge at the end of the shift to reliever to
proceed working in next shift.
Receiving 15 kgs of lap from blowroom dept & bringing
it to pilot plant
G
YARDAGE SAMPLE
CARDING,
DRAWFRAME,
SPEEDFRAME,RING
FRAME
WEAVER/SIDER
Activity Description
WLS No: YD/W/03
WORK LOAD DETAILS SHEET
YDD
Shifts A
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 1 1 1 -
Designation Proposed Manpower 1 1 1 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 1 10.00 10.00
2
1 1 10.00 10.00
3
1 1 45.00 45.00
4
1 1 15.00 15.00
5
1 1 45.00 45.00
6 1 1 15.00 15.00
7
1 1 5.00 5.00
A 145.00
B 13
C 163.85
D 450
E 36.41%
F 1
G 36.41%
Remarks:
The above workload is the operator's manual workload. But the operator has to wait during the
machine cycle time.
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Look after the 24 drums TFO m/c which will be
running throughout the shift
Run the new material on TFO before discharging his
duties
Carrying the final yarn from pilot plant to packing
To give the charge at the end of shift to reliever to
proceed working in next shift.
Basic Workload per Shift ( in man minutes)
SAVIO, CHEESE
WINDING,TFO
WEAVER/SIDER
Activity Description
Take charge of his duty
Take out the doff and make cones at winding
Simultaneously make cheeses of the winded cones
WLS No: YD/W/03 A
WORK LOAD DETAILS SHEET
YDD
Shifts A B C G
YARDAGE SAMPLE
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 1
Designation Proposed Manpower - - - 1
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 1 4.72 4.72
2
1 1 40.00 40.00
3 1 1 12.00 12.00
4
1 1 35.00 35.00
5
1 1 30.00 30.00
6 1 1 20.00 20.00
7
1 1 15.00 15.00
8
1 5.00
A 161.72
B 13
C 182.74
D 480
E 38.07%
F 1
G 38.07% Proposed Utilisation(%)
Remarks:
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Checking wrapping at R/F stage & provide final yarn
sample to SQC for quality checking.
Send final yarn to packing dept. yarn sample of each lot
made in pilot plant to ydd lab for shade checking.
Keep 1/2 kg of new shade in library
Random checking of m/c's parameter as per requirement
Sending material for conditioning if required.
YARDAGE SAMPLE
MONITOR
Activity Description
To check lap weight coming from blow room line.
To change gauge of card, set drawframe wrapping &
speed frame according to count.
To set the R/F program according to count
WLS No: YD/W/04
WORK LOAD DETAILS SHEET
YDD
Shifts A B C G
PILOT PLANT
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 1
Designation Proposed Manpower - - - 1
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
1
15
cones
45.00 45.00
2 1 1 90.00 90.00
3
1
15
cards
75.00 75.00
4
1 1 36.00 36.00
5
1 1 100.00 100.00
6 1 1 8.00 8.00
7 1 1 45.00 45.00
A 399.00
B 13
C 450.87
D 480
E 93.93%
F 1
G 93.93%
Remarks:
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Preparation of yarn shade ticket of each & every final
yarn lot & out sourced yarn for export quality to check
data values through CCMS(5-6 outside yarn avg.)
Making tuffts of dope dyed viscose & polyster to check
delta values through CCMS & keep record in sample
register (8-10 tuffts)
House keeping of dark room
Filling the shade consistency card after shade checking
Basic Workload per Shift ( in man minutes)
SHADE CHECKING
HELPER
Activity Description
Bring the yarn sample cones from BTM for shade
checking
Noting down mixing details of Elegant and BTM.
Preparation of shade consistency card for shade
checking.
WLS No: YD/W/05
WORK LOAD DETAILS SHEET
YDD
Shifts A B C G
YD LAB
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
6. WEAVING - PREPARATORY
________________________________________________________________________________________
National Productivity Council, Bangalore.
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___________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
6.0
6.1
I II III G T I II III G T
1 Warping Warper 5 5 5 - 15 5 5 5 - 15
Creel Boy 5 5 5 - 15 3 3 3 - 9
Fitter 1 1 1 - 3 - - - 1 1
Rewinder 6 6 6 - 18 5 5 5 - 15
Cleaner 1 1 1 - 3 1 1 1 - 3
Loose Packer 2 2 - - 4 1 1 - - 2
Godown Man 2 2 - - 4 2 2 - - 4
2 Drawing Reed man - - - 1 1 - - - - -
Cleaner - - - 1 1 - - - - -
Pinner 4 4 4 - 12 2 2 2 - 6
Drawer & Reacher 16 10 6 5 37 10 10 10 - 30
Beam Colie 3 3 3 - 9 2 2 2 - 6
Total 45 39 31 7 122 31 31 28 1 91
WEAVING - PREPARATORY
Manpower Deployment
S. No Section / Work area Designation
Present Manpower Proposed Manpower
Remarks
_________________________________________________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
6.0
6.2
6.2.1
a)
b)
c)
d)
e)
f)
g)
h)
i)
WEAVING - PREPARATORY
Proposed Changes & Observations
A deployment of 5 personnel in the rewinding section is recommended instead of the
present deployment of 6 per shift. For the 4 personnel recommended in the viscose area
the utilization works out to be 50.72 % per person per shift and for the one person
recommended in the polyester area, the utilization works out to be 82 % per shift. The
5 member crew has to manage the rewinding machines. The personnel may interchange
positions so that the workload evens out for all the personnel.
Proposed Changes
One maintenance fitter per shift is not being recommended. Instead one Fitter in the
general shift is being recommended. This is subject to certain activities to be performed
by the production personnel.
Deploy three creel boys per shift instead of the present deployment of 5 per shift. Two
creel boys are for machines 1,2 and 3 and two creel boys are for machines 4,5.
Beam colie- deploy two personnel in general shift instead of the present deployment of
three, based on workload
Position of Reed man in the general shift is not being recommended. These activities
may in the future be performed by the shift cleaner. The combined workload is detailed
in the workload sheet WGP/08
Position of cleaner in the general shift for the drawing area is not being recommended.
These activities may in the future be performed by the shift cleaner. The combined
workload is detailed in the workload sheet WGP/08
For pinning 8000 ends per shift a crew of two personnel is sufficient. Utilization for
each person works out to be 21.45 % per shift.
Drawer & Reacher - Deploy 10 personnel per shift for the processing of 5 beams,
based on workload
Deploy one loose packer per shift instead of the present deployment of two per shift
based on workload.
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
6.0
6.3
S.No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Drawer and Reacher WGP/14
Beam Colie WGP/15
Workload Sheets Summary
WLS Number Area of work
Loose packer WGP/09
Godown man WGP/10
Rewinders - polyester WGP/07
Shift Cleaner WGP/08
Shift fitter WGP/05
WGP/06
Pinner WGP/13
Reed man WGP/11
General shift cleaner WGP/12
WEAVING - PREPARATORY
Rewinders - viscose
Warper - machine 1,2,3 WGP/01
Warper - machine 4,5 WGP/02
Creel Boy - machine 1,2,3 WGP/03
Creel Boy - machine 4,5 WGP/04
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Present Manpower 3 3 3 -
Proposed Manpower 3 3 3 -
S.
No
Crew
Size
Freq/
beam
Basic
Time
(mins)
Total
Time
(min)
1
2 1/1 20.35 20.35
2
2 1/1 8.41 8.41
3
2 1/1 6.48 6.48
4
2 1/1 1.08 1.08
5
1 1/1 1.27 1.27
6 1 1/1 1.67 1.67
7
1 29/1 0.96 27.82
8
1 1/1 1.64 1.64
9
1 1/1 5.49 5.49
10
2 1/1 13.64 13.64
11
- 1/1 2.00
WLS No:WGP/01
WORK LOAD DETAILS SHEET
Department Weaving
Shifts A B C G
Section
Pass thread from V-reed to be tied them to the Roller
Preparatory
Work Centre Warping
Designation Warper
Set the Count,warp length and No of ends in the electronic
display
Make Long rope to insert Leese in the sections required
Tie the combined ends(after passing them through V-reed) to
the drum and insert leesing;same step being repeated for
every section
Activity Description
Manual Element
Take the cone out of the packet and load on to the creel(iron
bars) i.e. 148 cones
Take the cone out of the packet and load on the other side of
the creel(for selvedge purpose)
Setting stop motion pin and check tension in the threads and
tie them upto the leese reed
Attend to thread cuts(1 per 29 sections)
Make adjustments i.e. tie bolts ,adjust drums,unhook all
sections onto the iron bar ,place them onto the beam and tie
the ends onto the beam
Take out remaining cones as the full beam has been
prepared and place them in a bag;Both from creel and
selvedge
Machine Elements
Rotate @550 meters/min(actual 450 meters/min)i.e for 1
section of 1020 meters
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Present Manpower 3 3 3 -
Proposed Manpower 3 3 3 -
S.
No
Crew
Size
Freq/
beam
Basic
Time
(mins)
Total
Time
(min)
WLS No:WGP/01
WORK LOAD DETAILS SHEET
Department Weaving
Shifts A B C G
Section Preparatory
Work Centre Warping
Designation Warper
Activity Description
12
- 1/1 10.33
A 87.85
B 6
C 527.10
D 13
E 595.62
F 1350
G 44.12%
H 3
I 44.12%
Roll onto the beam@100 meters/min;Total warping
length=1020 metres
Basic Workload per Beam ( in man minutes)
Frequency per Shift;No of beams to make
Basic Workload per Shift ( in man minutes)
Proposed Manpower per shift
Proposed Utilisation(%)
Remarks:1) Number of beams to make has been taken as per data provided by the management i.e.
30000 mtrs of the fabric is to be warped per day or 2000 mtrs per m/c.In one time average 1000
mtrs being warped on an average therefore warping is being done 2 times per m/c per shift
Rest & Relaxation Allowances ( % )
Total Workload per Shift( in man minutes )
Net Available man-mins per shift
Present Utilisation(%)
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Present Manpower 2 2 2 -
Proposed Manpower 2 2 2 -
S.
No
Crew
Size
Freq/
beam
Basic
Time
Total Time
(min)
1 2 1/1 16.47 16.47
2
2 1/1 8.83 8.83
3
2 1/1 4.81 4.81
4 2 1/1 1.99 1.99
5
1 1/1 1.26 1.26
6
1 1/1 0.87 0.87
7
1 44/1 39.23 39.23
8 1 1/1 1.04 1.04
9
1 1/1 7.73 7.73
10
2 1/1 11.61 11.61
11
- 1/1 1.84
12
- 1/1 8.29
A 93.82
B 4
C 375.30
D 13
E 424.09
F 900
G 47.12%
H 2
I 47.12%
WLS No:WGP/02
WORK LOAD DETAILS SHEET
Department Weaving
Shifts A B C G
Section
Pass thread from V-reed to be tied them to the Roller
Preparatory
Work Centre Warping
Designation Warper
Set the Count,warp length and No of ends in the
electronic display
Make Long rope to insert Leese in the sections
required
Tie the combined ends(after passing them through V-
reed) to the drum and insert leesing;same step being
repeated for every section
Activity Description
Manual Element
Take the cone out of the packet and load on the other
side of the creel(for selvedge purpose)
Setting stop motion pin and check tension in the
threads and tie them upto the leese reed
Roll onto the beam@100 meters/min;Total warping
length=829 metres
Basic Workload per Beam ( in man minutes)
Frequency per Shift;No of beams to make
Basic Workload per Shift ( in man minutes)
Attend to thread cuts(1 per 44 sections)
Make adjustments i.e. tie bolts ,adjust drums,unhook
all sections onto the iron bar ,place them onto the
beam and tie the ends onto the beam
Take out remaining cones as the full beam has been
prepared and place them in a bag;Both from creel and
selvedge
Machine Elements
Rotate @550 meters/min(actual 450 meters/min)i.e
for 1 section of 829 meters
Proposed Manpower per shift
Proposed Utilisation(%)
Rest & Relaxation Allowances ( % )
Total Workload per Shift( in man minutes )
Net Available man-mins per shift
Present Utilisation(%)
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Present Manpower 3 3 3 -
Proposed Manpower 2 2 2 -
S.
No
Crew
Size
Freq/
beam
Basic
Time
Total
Time
(mins)
1
2 1/1 20.34 20.34
2
2 1/1 8.41 8.41
3
2 1/1 6.48 6.48
4
2 1/1 1.08 1.08
5
1 1/1 5.34 5.34
6
2 1/1 9.44 9.44
7
1 1/1 28.00 28.00
8
1 1/1 6.34 6.34
A 85.43
B 6
C 90
D 602.55
E 13
F 680.88
G 1350
H 50.44%
I 2
J 75.65%
WLS No:WGP/03
WORK LOAD DETAILS SHEET
Department Weaving
Shifts A B C G
Section
Activity Description
Manual Element
Take the cone out of the packet and load on to the creel(iron
bars) i.e. 148 cones
Take the cone out of the packet and load on the other side of
the creel(for selvedge purpose)
Setting stop motion pin and check tension in the threads and
tie them upto the leese reed
Preparatory
Work Centre Warping
Designation Creel Boy
Put oil in the m/c oiling tank from storage tank
Basic Workload per Beam ( in man minutes)
Frequency per Shift;No of beams to make
Relieve Warper for lunch
Pass thread from V-reed to be tied them to the Roller
Bring empty beam from empty beam space and fit bolts
Take out remaining cones as the full beam has been prepared
and place them in a bag;Both from creel and selvedge
Airing of workplace with air-pipe
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Remarks:
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload per Shift( in man minutes )
Net Available man-mins per shift
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Present Manpower 2 2 2 -
Proposed Manpower 1 1 1 -
S. No
Crew
Size
Freq/
beam
Basic
Time
Total
Time
(mins)
1
2 1/1 16.47 16.47
2
2 1/1 8.83 8.83
3
2 1/1 4.81 4.81
4
2 1/1 1.99 1.99
5
1 1/1 5.51 5.51
6
2 1/1 11.61 11.61
7
1 1/1 28.00 28.00
8
1 1/1 6.23 6.23
A 83.43
B 4
C 60
D 393.73
E 13
F 444.91
G 900
H 49.43%
I 1
J 98.87%
WLS No:WGP/04
WORK LOAD DETAILS SHEET
Department Weaving
Shifts A B C G
Section
Activity Description
Manual Element
Take the cone out of the packet and load on to the
creel(iron bars) i.e. 120 cones
Take the cone out of the packet and load on the other
side of the creel(for selvedge purpose)
Setting stop motion pin and check tension in the threads
and tie them upto the leese reed
Preparatory
Work Centre Warping
Designation Creel boy
Put oil in the m/c oiling tank from storage tank
Basic Workload per Beam ( in man minutes)
Frequency per Shift;No of beams to make
Relieve Warper for lunch ( in man minutes)
Pass thread from V-reed to be tied them to the Roller
Bring empty beam from empty beam space and fit bolts
Take out remaining cones as the full beam has been
prepared and place them in a bag;Both from creel and
selvedge
Airing of workplace with air-pipe
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Remarks:
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload per Shift( in man minutes )
Net Available man-mins per shift
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Present Manpower 1 1 1 -
Proposed Manpower - - - 1
S. No
Crew
Size
Freq/
Shift
Basic
Time
(mins)
Total
Time
(mins)
1 1 10 2.00 20.00
2
1 4 0.50 2.00
3
3.1 1 1/3 5.00 1.67
3.2 1 1/3 10.00 3.33
3.3
1 1 3.75 3.75
4
1 5 0.69 3.47
5
1 5 2.00 10.00
6
1 1/18 424.78 23.60
7
1 15.00 15.00
A 82.82
B 13
C 93.58
D 450
E 20.80%
F 1
G 19.50%
Oil lubrication (rewinding - 20 spindles / shift)
Activity Description
Attend to the breakdowns in the various machines
Set the beam flange after warping
Start the idle spindle running on the rewinding machine
Check the tightness of the bolts in the individual beams,
tighten if required
Unload the beam after warping from the warping
machine
Perform preventive maintenance of the machines in the
presence of the supervisor
Perform the oiling and greasing for all the warping
machines and the rewinding machines
Oil lubrication (warping )
G
Section
Greasing (warping machines)
Preparatory
Work Warping and Rewinding
Designation Fitter
Proposed Manpower per day
Proposed Utilisation(%)
WLS No:WGP/05
WORK LOAD DETAILS SHEET
Department Weaving
Shifts A B C
3. Keeping the above points in mind, this position is being recommended to be manned only in the
general shift.
4. Some of the rewinders will have to be trained in the performance of the activity 2 in the shifts B
and C respectively.
1 It is observed that the utilization per shift is only 20 %. Activities 1,3 and 5 may be shifted to the
warper / warper helper as these do not require any complex routines to be performed.
2. No data regarding the breakown attendance and the preventive maintenace performed has been
furnished. The details provided here are based on discussions with the Maintenace In Charge and the
Fitter. During my study for a shift no breakdown attendance has been observed.
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Remarks:
Net Available man-mins
Present Utilisation(%)
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Present Manpower 4 4 4 -
Proposed Manpower 4 4 4 -
S.
No
Crew
Size
Freq/
Shift
Basic
Time
(mins)
man
mins
Total
Time
(mins)
1
4 733.91 733.91
2
3
4
5
6
7
8
9
10
11
60.00 60.00
A 793.91
B 15
C 913.00
D 450
E 50.72%
F 4
G 50.72%
Remarks:
1. The rewinding section is to be manned by a crew of 5 personnel. During the shift itself the
personnel may interchange positions to even out the workloads for the individuals.
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Place the unused cones in the storage area and back
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Others - discussions with the supervisors etc
Place the big poly bag aside and back
Attend to problems such as thread cuts, changing the small
input rolls etc.,
Pull the big poly bag from near to the weighing machine to
the working area
Place cones from the big poly bag onto the machine
Connect the thread to the empty cone, wind and start the
cones
Place the completed big rolls into a big poly bag
WLS No:WGP/06
WORK LOAD DETAILS SHEET
Department Weaving
Shifts A B
Preparatory
C G
Section
Place completed roll in the poly cover and place the same on
the machine top
Prepare slips and paste on the inside of the cone
Get cones, place cones on the machine
Work Warping and Rewinding
Designation Rewinders viscose
Activity Description
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Present Manpower 2 2 2 -
Proposed Manpower 1 1 1 -
S.
No
Crew
Size
Freq/
Shift
Basic
Time
(mins)
man
mins
Total
Time
(mins)
1
2 305.99 305.99
2
3
4
5
6
7
8
9
10
11
15.00 15.00
A 320.99
B 15
C 369.14
D 450
E 41.02%
F 1
G 82.03%
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Net Available man-mins
1. The rewinding section is to be manned by a crew of 5 personnel. During the shift itself the
personnel may interchange positions to even out the workloads for the individuals.
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Remarks:
Connect the thread to the empty cone, wind and start the
cones
Place the completed big rolls into a big poly bag
Place the big poly bag aside and back
Attend to problems such as thread cuts, changing the small
input rolls etc.,
Others - discussions with the supervisors etc
Basic Workload per Shift ( in man minutes)
Place completed roll in the poly cover and place the same
on the machine top
Prepare slips and paste on the inside of the cone
Get cones, place cones on the machine
Place the unused cones in the storage area and back
Pull the big poly bag from near to the weighing machine to
the working area
Place cones from the big poly bag onto the machine
Preparatory
Work Warping and Rewinding
Designatio
n
Rewinder - polyester
Activity Description
WLS No:WGP/07
WORK LOAD DETAILS SHEET
Departmen Weaving
Shifts A B C G
Section
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Present Manpower 1 1 1 -
Proposed Manpower 1 1 1 -
S.
No
Crew
Size
Freq/
Shift
Basic
Time
(mins)
man
mins
Total
Time
(mins)
1
2
3
4 1 99.20 99.20
5
1 115.70 115.70
A 577.51
B 13
C 652.58
D 450
E 48.34%
F 3
G 48.34%
Total Workload ( in man minutes )
Net Available man-mins per day
362.61 362.61
Proposed Utilisation(%)
General shift cleaning works
Present Utilisation(%)
1
Basic Workload per Shift ( in man minutes)
B Shift : (362.61/3 + 99.20/2 + 115.70/2) * 1.13 = 258 minutes and utilization = 57.33 %
C Shift : (362.61 /3)*1.13= 137 minutes and utilization = 30.35 %
Remarks:
1. The utilization for this position holder in the three shifts will be as follows:
Proposed Manpower per day
A shift : (362.61/3 + 99.20/2 + 115.70/2) * 1.13 = 258 minutes and utilization = 57.33 %
Rest & Relaxation Allowances ( % )
Clean the warping area (collect waste, collect the creel
covers, waste cones etc., collect in a poly cover and
dispose in the disposal area). Clean by both the broom
stick and the long handled broom
Clean rewinding area by broomstick, collect wastes in the
polycover and dispose in the disposal area
Reed man activities
Clean godown area by broomstick, collect wastes in the
polycover and dispose in the disposal area
Preparatory
Work Warping and Rewinding
Designation Cleaner
Activity Description
WLS No:WGP/08
WORK LOAD DETAILS SHEET
Department Weaving
Shifts A B C G
Section
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Weaving
Preparatory
Preparatory Present Manpower 2 2 - -
Loose Packer Proposed Manpower 1 1 - -
Sl. No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
1 5 18.07 90.33
2 1 5 0.85 4.24
3
1 5 0.53 2.65
4
1 1 5.21 5.21
5 1 1 2.11 2.11
6 1 1 4.31 4.31
7 1 1 2.21 2.21
8
1 20 2.61 52.27
9
1 20 1.78 35.51
10
1 20 0.83 16.66
11
1 20 0.46 9.23
12 1 20 0.28 5.56
13
1 2 0.95 1.91
14 1 2 0.35 0.71
15
1 20 0.88 17.59
16 1 1 0.35 0.35
A 250.85
B 13
C 283.47
D 900
E 31.50%
F 1
G 62.99%
Section
Activity Description
Packing empty cones coming from Loom Shed and
shift to godown
Shift 400 empty cones in a separate bag coming from the
Loom Shed;segregation is done according to color of the
cones
Department
WLS No:WGP/09
WORK LOAD DETAILS SHEET
Shifts A B C G
Shift the bags after weighing to be sent for reuse
Load 10 bags on trolley
Carry 5 bags upto yarn godown entry and unload
Return with empty trolley
For transferring extra bags to upwrad godown for
external sales and use
Open the stitch of the bags
Transfer cones from 1 bag to another(28 cones)
Prepare,stitch and put a sample cone outside the bag
Put details on the bag viz lot no and number of cones with
a marker
Bring trolley to load bags for transfer
Load 5 bags on to the trolley
Proposed Utilisation(%)
Remarks:
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Work Centre
Designation
Proposed Manpower per shift
Carry upto weighing m/c
Weigh the bags (deduce 200 gm of bag wt and 350 gms
of card board of cone and note in the register) and put
aside
Return for next set
Basic Workload per Shift ( in man minutes)
Stitich the new bag and put sample cone outside new bag
Note the count lot,no and shade no in register
Put new count no on the register
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Present Manpower 2 2 - -
Proposed Manpower 2 2 - -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 2 7 1.26 17.64
2 2 7 2.31 32.36
3 2 6 1.01 12.11
4 2 5 1.31 13.12
5 2 5 2.16 21.58
6 2 5 0.35 3.55
7 2 5 1.07 10.65
8 2 5 0.35 3.53
9 2 4 1.62 12.99
10 2 2 1.23 4.92
11 2 2 5.81 23.23
12 2 2 2.74 10.96
13 1 5 3.87 19.36
14 1 5 0.97 4.85
15 1 5 0.54 2.72
16 1 2 1.17 2.35
17 1 1 0.75 0.75
Activity Description
Arrange the yarn on warping m/c
Destack and load 6 bags(at a time) of 64 kg each on two
trolley
Designation
WLS No:WGP/10
WORK LOAD DETAILS SHEET
Shifts A B C G
Unload all 3 bags to the place
Return and carrying the bags to Weft godown 2(for
another set of 70 looms)
Unload all 3 bags to the place
Return with empty trolley for next load
Carrying upto warping m/c and dump
Return with empty trolley for next load
Put the yarn from main godown to weft godown
Destack and load 6 bags(at a time) of 64 kg each on
trolley
Carrying the bags to Weft godown 1(for 1 set of 70
looms)
Carry bag to yarn godown or rewinding
Return empty handed for next bag
From Weft Godown to Loose Section
Loading 6 bags(containing semi used cones) on to the
trolley
Carrying the trolley upto rewinding and place after
weighing
Return to take next load
Packing cones left after Warping to be transferred
either to rewinding or to godown
Shifting cones from 1 bag(48 cones in 1 bag) to another
according to their destination
Prepare and stitch the bag
Write lot no,count and no of cones on the bag
Weaving
Preparatory
Preparatory
Godown Man
Department
Section
Work
Centre
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Present Manpower 2 2 - -
Proposed Manpower 2 2 - -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
Activity Description
Designation
WLS No:WGP/10
WORK LOAD DETAILS SHEET
Shifts A B C G
Weaving
Preparatory
Preparatory
Godown Man
Department
Section
Work
Centre
18 1 1 95.84 95.84
A 292.51
B 13
C 330.53
D 900
E 36.73%
F 2
G 36.73% Proposed Utilisation(%)
Remarks:Since 6000 mtrs have to be given to warping m/c i.e. per shift 31.2 bags.Since at a time 6
bags can be taken to warping by two persons therefore they will deliver all the bags in 7 trips
Check the loose yarn available for next day program
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Present Manpower - - - 1
Proposed Manpower - - - -
S. No
Crew
Size
Freq/
Shift
Basic
Time
(mins)
Total
Time
(mins)
1
1 1 5 5
2
2.1 1 7 0.27 1.89
2.2 1 14 0.71 9.98
2.3 1 7 1.57 10.99
2.4 1 14 3.05 42.63
2.5 1 7 2.02 14.12
2.6 1 14 0.25 3.52
2.7 1 14 0.16 2.26
3
3.1 1 1 0.42 0.42
3.2
1 2 0.83 1.65
3.3 1 2 1.05 2.10
3.4 1 2 0.47 0.93
3.5 1 2 0.11 0.23
4
4.1
4.2
4.3
A 115.70
B 13
C 130.75
D 480
E 27.24%
F -
G -
Stack reed
Clean the reed using the cotton waste
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Basic Workload per Shift ( in man minutes)
Activity Description
Cut damaged reeds to smaller sizes, using a saw
Clean the reed using the polishing piece
Adjust the gap in the reed using the plier
Place reed on the work table, clean with compressed air
Clean reed with wire brush
Clean reed with cotton waste
Other miscellaneous works
Pick reed, place on the work table, clean using the wire
Clean the reed using emery paper -both sides
Proposed Utilisation(%)
Remarks:
20
In case the reeds are damaged, provide the information to
the supervisor who will make the necessary entries in the
computer
Go the machine area, using the plier adjust the reed gap
At the beginning of the shift - switch on the bulb, adjust,
clean the work area, collect tools and place on the work
table
Sultex, Dornier reeds
Transport reeds from the ground floor to the first floor
Net Available man-mins
Present Utilisation(%)
Preparatory
Work Drawing
Designation Reed Man
1. The position of the Reed man is not being recommended and this activity is shifted to shift cleaner
Keep the reed in the rack and back to workplace
Airjet
Walk to the airjet area
Proposed Manpower per shift
WLS No:WGP/11
WORK LOAD DETAILS SHEET
Department Weaving
Shifts A B C G
Section
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Present
Manpower
- - - 1
Proposed
Manpower
- - - -
S. No
Crew
Size
Freq/
Shift
Basic
Time
(mins)
man mins
Total
Time
(mins)
1
1.1 1 1 3.57 3.57
1.2 1 1 73.51 83.84
1.3 1 1 1.79 1.79
1.4 1 1 10.00 10.00
A 99.20
B 13
C 112.10
D 450
E 24.91%
F -
G -
Remarks:
1. The position of the general shift cleaner in the drawing area is not being recommended and this
activity is shifted to shift cleaner
Office
Collect the wastes in the poly cover and dispose
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Basic Workload per Shift ( in man minutes)
Activity Description
Clean
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Weft godown
Drawing work area
WLS No:WGP/12
WORK LOAD DETAILS SHEET
Department Weaving
Shifts A B C G
Section Preparatory
Work Centre Warping and Rewinding
Designation Cleaner
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Present Manpower 4 4 4 -
Proposed Manpower 2 2 2 -
S.
No
Crew
Size
Freq/
Shift
Basic
Time
(mins)
man mins
Total
Time
(mins)
1 2 2 2.48 9.90
2 1 2 1.32 2.64
3
3.1
1 2 0.68 1.35
3.2 1 2 0.45 0.90
3.3 1 2 0.30 0.60
3.4
2 2 0.89 3.54
3.5 1 2 1.58 3.15
3.6 1 2 0.79 1.58
4 2 8000 0.01 128.99
5
1 2 1.39 2.78
6
1 2 4.36 8.71
7 1 2 0.45 0.90
A 165.03
B 17
C 193.09
D 450
E 21.45%
F 2
G 21.45%
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Check, segregate sections
Make preparation for the pinning
Perform pinning
Proposed Utilisation(%)
Remarks:
1. For pinning 8000 ends one crew of two personnel is sufficient.
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Work Centre Warping and Rewinding
Designation Pinner
Activity Description
Position 2 rods, adjust
WLS No:WGP/13
WORK LOAD DETAILS SHEET
Department Weaving
Shifts
Bring 6 non serrated rods to the machine
Bring 2 small reeds, gunny bag to sit on, gunny bag to put
on the loom
Place the gunny bags on the loom
A B C G
Section
Keep the extra pins in the storage area
Insert 6 serrated rods into the pins stack, remove the non
serrated rods
Bring pins along with the serrated rods - 6 numbers
Fix the 6 non serrated rods to the 2 small reeds
Set tightness of gear
After pinning, clean up, collect the dropped pins, check for
the missing pins in the work performed and insert
whereever required
Preparatory
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Work Centre Present Manpower 16 10 6 5
Designation Proposed Manpower 10 10 10 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 2 1 43.05 86.10
2 1 1 5.04 5.04
3 1 1 2.57 2.57
4 2 1 1.29 2.57
5 1 1 2.47 2.47
6 1 1 5.48 5.48
7 1 1 3.47 3.47
8 1 1 4.48 4.48
9 1 1 3.87 3.87
10 2 1 8.64 17.28
11 2 1 386.50 400.00
A 533.33
B 13
C 602.67
D 900
E 66.96%
F 2
G 66.96%
Process
Make drawing and reaching process for making
monograms and tape(212 ends for both start and end of
the beam)
Drawing and reaching process for rest of the ends;4000
ends in this case
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Proposed Utilisation(%)
Remarks:Assumed that per shift 5 beams goes for gaiting so per shift 10 persons can do the required
work
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Setting the frame on drawn beam and adjust heald wire
Take 9 rods and insert in b/w frames
Tie all frames with threads and adjust iron rods
Take out the sheet cover from the beam and adjust the
beam ;Take all the knots on an iron bar and put the bar
above frame so that it suspends before frame
Tie reed on one side of the frame
Adjust threads on other side of the frame
Preparatory
Drawer & Reacher
Activity Description
Preparatory Activities
Prepare and adjust old frames coming from loom sheds to
be used for drawing and reaching purpose;10 frames+2
selvedge frames
Carrying the frame upto the drawn beam
Return for next frame
WLS No:WGP/14
WORK LOAD DETAILS SHEET
Weaving
Shifts A B C G
Preparatory Section
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Work Centre Present Manpower 3 3 3 -
Designation Proposed Manpower 2 2 2 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 5 1.14 5.71
2 1 5 1.01 5.05
3 1 5 1.80 8.98
4 1 5 0.72 3.58
5 2 5 5.61 56.09
6 2 5 4.75 47.50
7 2 5 3.59 35.90
8 1 8 0.37 2.95
9 1 8 2.19 17.49
10 1 5 2.04 10.20
11 1 5 2.27 11.36
12 1 5 2.10 10.52
13 2 10 2.22 44.40
A 259.71
B 13
C 293.48
D 1350
E 21.74%
F 2
G 32.61%
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Remarks:
Knotting Beam from Warping Section to Loom
Shed
Take out the beam after knotting and load the beam on
to the Beam Loader
Carry the knotted beam to the respective section in
Loom Shed
Return to warping section for next transfer
Placing the warp beam in its proper place
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Return to warping section for next transfer
Beam transfer from Drawing Section to Loom Shed
Setting Drawn Beam m/c on the drawn beam,setting
lever to insert beam and take out the beam loaded on
m/c
Carry the Drawn Beam m/c to the Loom Shed and
place at the required position
Return with another emptied Drawn Beam m/c to load
next beam from Drawing section
Empty beam from Loom Shed to Warping Section
Load empty beam on to the trolley
Carry the beam to empty beam section near Warping
Preparatory
Beam Colie
Activity Description
Beam transfer from Warping Section to Drawing
Unhook the beam after warping and take out the beam
Adjust the Beam Loader m/c beneath the beam and lift
the beam
Carry the beam to the Drawing section and release the
beam at its proper place
WLS No:WGP/15
WORK LOAD DETAILS SHEET
Weaving
Shifts A B C G
Preparatory Section
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
7. WEAVING - LOOMSHED
________________________________________________________________________________________
National Productivity Council, Bangalore.
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___________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
7.0
7.1
I II III G T I II III G T
1 Khata 1 Weaver 7 7 7 - 21 7 7 7 - 21
Weaver Helper 3 3 3 - 9 3 3 3 - 9
Fitter 1.5 1.5 1.5 - 4.5 1.5 1.5 1.5 - 4.5
Jobber 1 1 1 - 3 1 1 1 - 3
Roll Doffer 1.5 1.5 1.5 - 4.5 1 1 1 - 3
Charkhi Man 1 1 - - 2 - - - 1 1
Fancy Jobber - - - 1 1 - - - 1 1
Position combined
with the Fancy
Jobber of khata 2
Beam Gaitor 3 3 3 - 9 3 3 3 - 9
Weft Distributor 1 1 1 - 3 1 1 1 - 3
- -
2 Khata 2 Weaver 7 7 7 - 21 7 7 7 - 21
Weaver Helper 3 3 3 - 9 3 3 3 - 9
Fitter 1.5 1.5 1.5 - 4.5 1.5 1.5 1.5 - 4.5
Jobber 1 1 1 - 3 1 1 1 - 3
Roll Doffer 1.5 1.5 1.5 - 4.5 1 1 1 - 3
Fancy Jobber - - - 1 1 - - - - 0
Beam Gaitor 3 3 3 - 9 3 3 3 - 9
Weft Distributor 1 1 1 - 3 1 1 1 - 3
3
Both Khata 1 and Khata
2
Waste Picker - - - 6 6 - - - 4 4
Cleaners - Shift 2 2 2 - 6 2 2 2 - 6
Cleaners - General - - - 2 2 - - - 2 2
Total 39 39 38 10 126 37 37 37 8 119
Manpower Deployment
WEAVING - LOOMSHED
Proposed Manpower
Remarks S. No Section / Work area Designation
Present Manpower
_________________________________________________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
7.0
7.2
7.2.1
a)
b)
c)
d) Deploy 4 waste pickers instead of 6 waste pickers in the general shift, based on worklaod
WEAVING - LOOMSHED
Proposed Changes & Observations
Combine the positions of the two fancy jobbers (one in khata 1 and the other in khata 2).
The combined utilization will be 75.38 %. Deployment of one fancy jobber per day is
recommended.
Proposed Changes
Deploy one roll doffer per khata instead of the present deployment of 3 for two khatas.
The workload for the two roll doffers per shift is 84.22 %.
Deploy one Charkhi man for both the khatas and in general shift. The utilization is 48 %
for this position holder in each shift.
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
7.0
7.3
S.No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
WEAVING - LOOMSHED
Weaver Helper
Workload Sheets Summary
WLS Number
Fitter WGL/04
Area of work
Weaver WGL/01
WGL/03
Roll Doffer WGL/06
Charkhi Man WGL/07
Weaver WGL/02
Jobber WGL/05
Beam Gator - Airjet WGL/10
Beam Gator - Sultex WGL/11
Fancy Jobber - 1 WGL/08
Fancy Jobber - 2 WGL/09
Waste Picker WGL/14
Cleaner WGL/15
Beam Gator - Dornier WGL/12
Weft Distributor WGL/13
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Present Manpower 1 1 1 -
Proposed Manpower 1 1 1 -
S.
No
Crew
Size
Freq/
Shift
Basic
Time
(mins)
Total
Time
(mins)
A
1
1 1 2.11 2.11
2 1 90 1.31 117.90
3 1 120 1.08 130.08
4
1 55 0.58 32.08
5
1 2 5.28 10.55
6
1 27.93 27.93
7
1 10.00 10.00
A 330.65
B 17
C 386.86
D 450
E 85.97%
F 1
G 85.97%
To check the fabric of all 10 looms for quality, every two
hours
Activity Description
At the time of shift starting put sign on all 10 looms
fabric. Indicating the shift change and date.
To attend (mend) filling (weft breakage).
Designation Weaver
WLS No:WGL/01
WORK LOAD DETAILS SHEET
Department Weaving
Shifts
Work Centre Khata 1
A B C G
Weaving
Basic Workload per Shift ( in man minutes)
To attend (mend) broken warp end
Dornier
Patrolling behind the looms to see if there is any crossing
or entanglement at the beam, and do the correction if
required.
Report any abnormality in terms of quality or working to
the supervisor
Section
To change weft cones when finished.and tie the tails of
the reserve cone
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Remarks:
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Present
Manpower
1* 1 1 -
Proposed
Manpower
1 1 1 -
*
1
2
N F X 1-X
Number of
machines
Factor derived
from finite
queuing tables
8 0.975 0.052 0.948
9 0.969 0.052 0.948
10 0.963 0.052 0.948
11 0.957 0.052 0.948
12 0.95 0.052 0.948
13 0.941 0.052 0.948
14 0.932 0.052 0.948
2.1
a
b
c
0.69
0.41
0.45
0.50
0.55
C G
One weaver for every 10 looms
0.60
0.64
Work Centre Khata 1
Designation Weaver
Operator
workload
0.92
WLS No:WGL/02
Department Weaving
Shifts A B
WORK LOAD DETAILS SHEET
Section Weaving
0.92
0.91
0.91
0.91
0.90
0.89
ME
Machine
efficiency
For the computation of the number of machines to be allocated to each weaver, we have
analyzed the machine efficiency and operator workload for different machine assignments.
The same is depicted in the table below:
Looms
Calculation for X value:
Time study was carried out to determine quantum of time spent on mending broken warp,
broken weft and other activities carried out in the shift by the weaver. For the mending of the
broken warp the weaver takes 1.31 minutes (including walking time) and for mending weft
breakages the weaver takes 1.08 minutes (including walking and taking 25 % breakage before
the thread enters the accumulator and 75 % after the thread has passed through the
accumulator).
OW
Multiplying these values with the respective frequencies per shift (90 per 10 machines per
shift for warp breakages and 120 per 10 machines per shift for weft breakages) we obtain the
total external work to be carried out by the weaver. This is determined to be 247.98 minutes
per 10 machines per shift. Per machine it is 24.80 minutes per shift. That is for getting output
from the machine for 480-24.80 = 455.20 minutes per shift, the machine has to be serviced
for 24.80 minutes, giving a value of X = 24.80/480 = 0.052
For X = 0.052 the different values of the machine efficiency and operator workload has been
computed and they are depicted in the table above. Based on the formulae provided in the
finite queuing tables the values of the machine efficiency and the operator workload are
derived. The same are plotted in a graph and it is observed that for N=10 machines we reach
a ideal combination of the machine efficiency and the operator workload.
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Present
Manpower
1* 1 1 -
Proposed
Manpower
1 1 1 -
C G
Work Centre Khata 1
Designation Weaver
WLS No:WGL/02
Department Weaving
Shifts A B
WORK LOAD DETAILS SHEET
Section Weaving
d The ideal combination is to allot 11 machines to each weaver, but as the layout is such that
there are 10 machines in one line, we recommend that the same to be continued.
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.87
0.88
0.89
0.90
0.91
0.92
0.93
1 2 3 4 5 6 7
ME Machine efficiency
OW Operator workload
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Present Manpower 1 1 1 -
Proposed Manpower 1 1 1
S.
No
Crew
Size
Freq/
Shift
Basic
Time
(mins)
man
mins
Total
Time
(mins)
1
2
1 5.6 4.00 22.40
3
1 135.00 135.00
4
1 6 5.28 31.66
5 1 5/6 25.64 21.28
6
1 10.00 10.00
7
1 10.00 10.00
A 230.34
B 17
C 269.50
D 450
E 59.89%
F 1
G 59.89%
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Remarks:
1 This activity is alrady performed by the Weaver himself, hence this need not be performed again
by the Weaver Helper also. Hence no time has been allocated for this activity here.
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Activity Description
To help in passing the knotting of newly knotted beams
To attend to machine whenever there is multiple breaks or
smash
Report any abnormality in terms of quality or working to
the supervisor
To check the fabric of all looms of his lines (2 lines in
sultex and dornier & 3 lines in airjet) for quality at
resumption *1
To change catch selvedge spool, when finished
To relieve the weaver for lunch (30 min) and tea (15 min)
of three lines in loomshed *2
To take quality round of his respective lines twice a shift
and sign
G
Section
Weaving
Work Centre Khata 1
Designation Weaver Helper
2. The workload has been computed based on the sum of the activities 2,3,4 and 6 detailed in the
weaver workload sheet. These are the activities that the weaver helper is supposed to perform when
he is relieving the weavers. This works out to be 86.62 min
3. One weaver helper for three lines in the loomshed is recommended. As seen in the workload sheet,
the workload per shift for any of the weaver helpers is 59.89 %.
WLS No:WGL/03
WORK LOAD DETAILS SHEET
Department Weaving
Shifts A B C
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Present Manpower 3 3 3 -
Proposed Manpower 3 3 3 -
S.
No
Crew
Size
Freq/
Shift
Basic
Time
(mins)
Total
Time
(mins)
1
1 3 10.00 30.00
2
3
4
1 3 20.00 60.00
5
1 1 6.26 6.26
6
1 1 6.09 6.09
7
1 1 9.34 9.34
A 231.69
B 15
C 266.44
D 450
E 59.21%
F 1
G 59.21%
To remove the heald frames,empty beam & droppins of
finished beam.
To take the round for selvedge,oil leakage,abnormal sound
or any abnormality related to machine.
At the time of beam gaiting adjust the reed space according
to fabric width.
To do the oiling & greasing of new gaited or knotted
looms.
Rest & Relaxation Allowances ( % )
120.00
To do the oiling of cutter scissor & rapier head.
To attend the weft breakage & selvedge problem.
1 1
Proposed Utilisation(%)
Remarks:
120.00
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
To take the reading of (warp breakage, weft breakage &
efficiency) at the time of shift end.
Basic Workload per Shift ( in man minutes)
Activity Description
Weaving
Work Centre Khata 1 & 2
Designation Fitter
WLS No:WGL/04
WORK LOAD DETAILS SHEET
Department Weaving
Shifts A B C G
Section
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Present Manpower 1 1 1 -
Proposed Manpower 1 1 1 -
S.
No
Crew
Size
Freq/
Shift
Basic
Time
(man
mins)
Total
Time
(mins)
1
1 1 15.00 15.00
2
1 1 35.00 35.00
3
1 2.43 30.00 72.90
4
1 15.00 15.00
5
1 15.00 15.00
6 1 15.00 15.00
7
A 167.90
B 15
C 193.09
D 450
E 42.91%
F 1
G 42.91%
Remarks:
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Net Available man-mins per day
Present Utilisation(%)
Proposed Manpower per day
Proposed Utilisation(%)
Activity Description
To allocate workmen in the department, if any shortage
then he has to arrange workers accordingly.
To take round of the department to ascertain the number
of beam gaiting expected in the shift and plan the man
power accordingly.
To start the new beam with the shift incharge.
To attend the machines for warp & weft breakages,
selvedge problems etc.
To report and attend (help to attend) any abnormal
machine in terms of quality or productivity to the
concerned shift incharge.
To attend minor breakdowns
To organise for warp or weft shortage if any
G
Section Weaving
Work Centre Khata 1
Designation Jobber
1. Activity 4 and 5 are primarily the responsibility of the weaver and weaver helper.
2. This role is a Team Leader role wherein the position holder is a link between the workmen and the
first level of management.
WLS No:WGL/05
WORK LOAD DETAILS SHEET
Department Weaving
Shifts A B C
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Present Manpower 3 3 3 -
Proposed Manpower 2 2 2 -
S. No
Crew
Size
Freq/
Shift
Basic
Time
(mins)
Total
Time
(mins)
1
1.1
1 120 0.63 75.08
1.2 1 120 0.48 57.84
1.3 1 120 0.29 34.78
1.4 1 120 1.39 167.14
1.5
1 120 2.39 286.20
2
1 3 0.80 2.39
3 1 1 30.00 30.00
3.1
3.2
3.3
A 653.43
B 16
C 757.97
D 450
E 56.15%
F 2
G 84.22%
Load empty spindle, lock, roll some fabric
Write details on completed roll by chalk
Transport completed roll to grey checking area
To cut the first one meter fabric from every new
gaited or knotted looms & keep that fabric in the
bucket for checking.
Others
Roll doffing
Proposed Manpower per shift
Proposed Utilisation(%)
Remarks:
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
To fix one small sample of the newly started quality
on loom for reference.
Discussion with operator, supervisor etc.,
B
Basic Workload per Shift ( in man minutes)
G
Load empty spindle onto trolley, return back to the
weaving section, check machine panel, unload empty
near machine
Activity Description
Weaving
Work Centre Khata 1 & 2
Designation Roll Doffer
C
Tear cloth, load completed roll onto trolley, keep
trolley aside
Section
To wrap the light shade qualities in polythene.
WLS No:WGL/06
WORK LOAD DETAILS SHEET
Department Weaving
Shifts A
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Present Manpower 1 1 - -
Proposed Manpower - - - 1
S.
No
Crew
Size
Freq/
Shift
Basic
Time
(mins)
man mins
Total
Time
(mins)
1
1 20.00 20.00
2
2.1
1 10 0.69 6.93
2.2 1 10 0.38 3.80
2.3 1 10 12.23 122.27
2.4 1 10 0.24 2.41
2.5 1 10 0.41 4.12
2.6
1 4 1.16 4.64
3
3.1
1 2 0.69 1.39
3.2
1 2 0.38 0.76
3.3
1 2 7.00 14.00
3.4
1 2 0.24 0.48
3.5
1 2 0.41 0.82
3.6 1 2 1.16 2.32
4
1 1 5.03 5.03
5
1 1 2.55 2.55
A 191.51
B 13
C 216.41
D 450
E 48.09%
F 1
G 48.09%
Lock the machine and adjust
Remarks:
1. As the utilization of this position holder is 48 %, possibility of deploying only one person in the
general shift has to be explored. The recommended manpower is one in the general shift.
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Wind new thread
Remove lock and keep completed spool in rack
Place new thread roll, connect
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Pass through the pins, reeds and connect
Total Workload ( in man minutes )
Lock the machine and adjust
Wind new thread
Pass through the pins, reeds and connect
Go to yarn godown, search for materials, get thread
spools, place them in the stand
Cut the selvedge (20 threads), knot, go to stand and
connect for monogram threads
Prepare the spools for monogram bobbin
Pick new spool, place in machine, remove old thread
and dispose into the dust bin
Remove lock and keep completed spool in rack
Place new thread roll, connect
Activity Description
Pick new spool, place in machine, remove old thread
and dispose into the dust bin
Weaving
Work Centre Khata 1 & 2
Designation Charkhi Man
To collect all the empty bobbins from the looms.
Prepare the spools for catch selvedge waste for
Dornier, Sultex and Picanol.
WLS No:WGL/07
WORK LOAD DETAILS SHEET
Department Weaving
Shifts A B C G
Section
________________________________________________________________________________________
National Productivity Council, Bangalore.
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Present Manpower - - - 1
Proposed Manpower - - - 1
S.
No
Crew
Size
Freq/
Shift
Basic
Time
(mins)
Total
Time
(mins)
1
1.1
1 6 10.00 60.00
1.2
1 6 6.00 36.00
1.3 1 6 1.00 6.00
2
2.1
1 3 22.25 66.75
2.2
1 2/25 66.75 5.34
2.2
1 3 11.36 34.08
2.3
1 3 1.00 3.00
A 211.17
B 13
C 238.62
D 450
E 53.03%
F 1
G 53.03%
Proposed Manpower per shift
Monogram
Punch holes of the required pattern on the sheet (done by
copying the existing pattern on the pattern being created)
Cut sheet to size, check visually, paste by fevibond and
scrape by emery, using a rod remove the glue from the
holes
Go to the loomshed and hang in the hanger
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Present Utilisation(%)
Activity Description
Punch holes of the required pattern on the sheet (partly
punching done manually, major portion done by copying the
existing pattern on the pattern being created)
Cut sheet to size, check visually, paste by fevibond and
scrape by emery, using a rod remove the glue from the
holes
Go to the loomshed and hang in the hanger
Total Workload ( in man minutes )
Net Available man-mins
Proposed Utilisation(%)
Remarks:
Weaving
Work Centre Khata 1
Designation Fancy Jobber
Punch holes of the required pattern on the sheet (done by
manual punching)
Body
WLS No:WGL/08
WORK LOAD DETAILS SHEET
Department Weaving
Shifts A B C G
Section
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Present Manpower - - - 1
Proposed Manpower - - - -
S.
No
Crew
Size
Freq/
Shift
Basic
Time
(mins)
Total
Time
(mins)
1
1 1 16.36 16.36
2
1 5 15.00 75.00
3
1 13/100 105.17 14.02
A 89.02
B 13
C 100.59
D 450
E 22.35%
F 1
G 22.35%
Remarks:
1. The utilization of this incumbent is 22.35 %. One person may be deployed for the Fancy Jobber
activity for both the khatas.
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Take a round of the dornier section and check for the
quality of the monograms. Incase of any non-conformity
found then correct the same
Prepare the monogram for the jacquard machines in the
dornier section
Perform preventive maintenance works on jacquard in
the dornier section
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Weaving
Work Centre Khata 1
Designation Fancy Jobber
Activity Description
WLS No:WGL/09
WORK LOAD DETAILS SHEET
Department Weaving
Shifts A B C G
Section
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 2 2 2 -
Designation Proposed Manpower 2 2 2 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
1 1.28 10.25 13.12
2
1 1.28 7.34
3
1 1.28 6.22
4
2 1.28 9.34 23.91
5
1 1.28 1.68 2.15
6 1 1.28 8.54 10.93
7
2 1.28 34.67 88.76
8
2 1.28 18.21 46.62
9
1 1.28 5.35 6.85
10
2 2 57.50 230.00
A 422.33
B 13
C 477.24
D 900
E 53.03%
F 2
G 53.03%
C G
Weaving
Airjet looms
Beam Gaitor
Activity Description
Preparatory Activities
To remove the heald frames,empty beam & droppins of
finished beam
WLS No:WGL/10
WORK LOAD DETAILS SHEET
Weaving
Shifts A B
To change the leno bobbin in airjet at the time of beam
change
Fitting and passing threads through the reed (Work is
done on both side i.e. on one side tyeing the ends of
previous beam to the new beam,fixing the reed and on the
other side adjusting bolts,run contrast patti to check for
weaving damages ,placing roller
Final adjustment and make 1 meter fresh fabric of new
gaited loom & rectify all cross ends.
Call the shift incharge for final,checking and hand over
the machine for production.
To get the machine clean with the help of loom cleaner.
To get the machines lubricated with the help of Fitters
Gait the new beam on loom.
Arrange and adjust the beam carrying m/c on to the Airjet
m/c
Put the correct weft yarn as per design on the loom card,
and run the machine with fresh fabric.
Remarks:
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
To pass the knots of knotted beam either of warping
knotting or loom knotting.
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 2 2 2 -
Designation Proposed Manpower 2 2 2 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
1 1.71 13.41 22.93
2
1 1.71 8.19
3
1 1.71 7.22
4
2 1.71 21.56 73.74
5
1 1.71 1.68 2.87
6
2 1.71 41.44 141.72
7
2 1.71 25.78 88.17
8
1 1.71 12.45 21.29
9
2 2 57.50 230.00
A 580.72
B 13
C 656.21
D 900
E 72.91%
F 2
G 72.91%
WLS No:WGL/11
WORK LOAD DETAILS SHEET
Weaving
Shifts A B G
Weaving
To pass the knots of knotted beam either of warping
knotting or loom knotting.
To get the machine clean with the help of loom
cleaner.
To get the machines lubricated with the help of
Fitters
Gait the new beam on loom.
Arrange and adjust the beam carrying m/c on to the
Sultex m/c
Put the correct weft yarn as per design on the loom
card, and run the machine with fresh fabric.
Sultex looms
Beam Gaitor
Activity Description
Fitting and passing threads through the reed (Work
is done on both side i.e. on one side tyeing the ends
of previous beam to the new beam,fixing the reed
and on the other side adjusting bolts,run contrast
patti to check for weaving damages ,placing roller
Drawing the ends in correct order and final
adjustment and make 1 meter fresh fabric of new
gaited loom & rectify all cross ends.
Call the shift incharge for final,checking and hand
over the machine for production.
Proposed Manpower per shift
Proposed Utilisation(%)
C
Preparatory Activities
To remove the heald frames,empty beam &
droppins of finished beam
Remarks:
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 2 2 2 -
Designation Proposed Manpower 2 2 2 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
1 1.71 21.11 36.10
2
1 1.71 11.12
3
1 1.71 6.47
4
2 1.71 16.46 56.29
5
1 1.71 1.82 3.11
6
2 1.71 75.22 257.25
7
2 1.71 32.43 110.91
8
1 1.71 19.45 33.26
9
2 2 57.50 230.00
A 726.93
B 13
C 821.43
D 900
E 91.27%
F 2
G 91.27%
Dornier looms
Beam Gaitor
Activity Description
Preparatory Activities
To remove the heald frames,empty beam & droppins
of finished beam
WLS No:WGL/12
WORK LOAD DETAILS SHEET
Weaving
Shifts A B
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Remarks:
C G
Weaving
Fitting and passing threads through the reed and fix
the correct Dobby card on the machine(Work is done
on both side and i.e.on one side tyeing the ends of
previous beam to the new beam,fixing the reed and
on the other side adjusting bolts,run contrast patti to
check for weaving damages ,placing roller etc)
Drawing the ends in correct order and final
adjustment and make 1 meter fresh fabric of new
gaited loom & rectify all cross ends.
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Net Available man-mins
To pass the knots of knotted beam either of warping
knotting or loom knotting.
To get the machine clean with the help of loom
cleaner.
To get the machines lubricated with the help of
Fitters
Gait the new beam on loom.
Arrange and adjust the beam carrying m/c on to the
Dornier m/c
Put the correct weft yarn as per design on the loom
card, and run the machine with fresh fabric.
Call the shift incharge for final,checking and hand
over the machine for production.
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 2 2 2 -
Designation Proposed Manpower 2 2 2 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
1 21 4.72 99.12
2
1 4 20.68 82.72
3
1 21 13.28 278.88
4
1 21 7.10 149.08
5 1 21 2.18 45.68
6
1 2 31.32 62.64
7
1 2 9.60 19.20
8
1 2 2.74 5.48
A 742.81
B 13
C 839.37
D 900
E 93.26%
F 2
G 93.26%
Activity Description
Open the bags and put the yarn in the racks as per
loom no wise(for 1 bag of 64 kg carrying 32 cones on
an average)
WLS No:WGL/13
WORK LOAD DETAILS SHEET
Weaving
Shifts A B C G
Weaving
Basic Workload per Shift ( in man minutes)
From Weft Godown to Loom shed
Inspecting and checking the requirements for each
m/c(total 140 m/c) and note on the paper
Fill the trolley (65-70 kg in a trolley) according to
requirement i.e as per beam ticket count, shade , lot
number
Carry the trolley to the respective m/cs and place in
the respective boxes(1 trolley can fulfil the
requirement of 3 m/cs )
Return to take next load
Loomshed
Weft Distributor
Proposed Manpower per shift
From Looms shed to Weft Godown
Collecting semi used cones into trolley from 140 m/c
Carrying the trolley to weft godown and place in bags
to be taken to rewinding m/c
Return to take next load
Proposed Utilisation(%)
Remarks:30000 mtr=10000 kgs; by 60/40 rule,60 percent will go to warping and 40 percent to the
weft godown.So 4000 mtrs i.e.21 bags will be transferred to the weft godown and same will be
distributed in the loom per shift
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 6
Designation Proposed Manpower - - - 4
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
1 6 108.54 651.24
2 1 3 105.76 317.28
3
1 3 75.45 226.35
4
1 3 72.58 217.74
5 1 1 90.54 90.54
A 1503.15
B 13
C 1698.56
D 2880
E 58.98%
F 4
G 88.47%
WLS No:WGL/14
WORK LOAD DETAILS SHEET
Weaving
Shifts A B C G
Weaving
Clean the m/c with the help of cleaner
Collect waste(empty bags,polythene waste,gatta) from
each m/c and pack it separately
To segregate all types of yarn waste,length wise and
pack it
To segregate all types of fabric waste and pack it
Loom Shed
Waste Picker
Activity Description
Collect empty polythene,paper cones and plastic cones
in 3 separate bags
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Remarks:
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Net Available man-mins
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 2 2 2 2
Designation Proposed Manpower 2 2 2 2
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
1 9 22.89 206.01
2 1 6 66.78 400.68
3
1 3 31.11 93.33
4
1 3 4.34 13.02
5
1 3 14.67 44.01
6
1 9 24.33 218.97
7
1 6 25.44 152.64
A 1128.66
B 13
C 1275.39
D 1860
E 68.57%
F 4
G 70.85%
Activity Description
To remove the catch selvedge waste from waste box with
work divided among 3 workmen each having 40(sultex and
picanol),48(Donear) and 40(Airjet) m/c
WLS No:WGL/15
WORK LOAD DETAILS SHEET
Weaving
Shifts A B C G
AirJet/sultex/ dornier
Rest & Relaxation Allowances ( % )
To clean the running machines with air pressure .
Help the fitter in removing the old heald frame set, drop
pins and reed from the machines where the beam has
finished.
Take the old set of drop pins, reed and frames to the
drawing in section carefully
To do the thorough cleaning of new gaited looms with air
pressure & cloth.
Loom Shed
Cleaner
Proposed Utilisation(%)
To keep the loom shed neat & clean.
To collect the paper cones & polyethene, and transfer it to
bardana godown
Basic Workload per Shift ( in man minutes)
Remarks:
The above worload sheets reflects the activity of two personnel in general shift and two personnel in
shift
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
8 A. WEAVING MAINTENANCE - MECHANICAL
MAINTENANCE
________________________________________________________________________________________
National Productivity Council, Bangalore.
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___________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
8 A
8.1 A
I II III G T I II III G T
1 AIRJET FITTER - - - 1 1 - - - 2 2
2 DORNIER FITTER - - - 2 2 - - - 2 2
3 SULTEX FITTER - - - 2 2 - - - 2 2
Total 0 0 0 5 5 0 0 0 6 6
Manpower Deployment
WEAVING MAINTENANCE - MECHANICAL MAINTENANCE
Proposed Manpower
Remarks S. No Section / Work area Designation
Present Manpower
_________________________________________________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
8 A
8.2 A
8.2.1 A
a)
8.2.2
a)
b)
c)
-
-
-
-
d)
Two fitters in each area are being proposed keeping in mind the importance of
getting the equipment up and running in the least possible time and to increase
the production output. The utilization for the two fitters in the sultex section
works out to be 77 % whereas in the dornier and the airjet sections the
utilization is 42.82 % and 38.56 %, after allowing for a loading factor of 80 %.
Observations
Technically if we proceed only as per workload, it is possible to combine both
the airjet and the dornier sections and a common crew of two fitters may man
the combined sections. However analyzing the data of breakdown maintenance
for a period of two months it is observed that in the span of two months there
has been one occurence of a simultaneous occurence in the airjet and the
dornier areas. There has also been two breakdowns in the airjet area on one day
and in the dornier areas for two days. Keeping in mind the possibility of
simultaneous occurence of breakdowns inside the sections and between the
sections, two seperate crews are being recommended for each of the above
mentioned areas. It is furthur recommeded that the company analyze the
occurence of the breakdowns in the two sections for a period of 2-3 years to
obtain a reasonable estimate of the simultaneous occurences. If the
simultaneous occurences are not many then a common crew of two fitters may
be deployed to take care of both the sections.
WEAVING MAINTENANCE - MECHANICAL
Proposed Changes & Observations
Deploy two fitters in the general shift in the airjet area instead of the present
deployment of one in the general shift
Proposed Changes
The following need improvements to make the maintenance function more
effective
Records keeping
The start and end times for both the preventive maintenance and the breakdown
maintenance to be maintained. This would help in the analysis of the
breakdowns and in maintenance planning
The manpower has been computed with a loading factor of 80 % for the
maintenance personnel. The 80 % loading has been considered to take into
account the following
Variation in machine availability
Collection & deposit of tools, dress change
Effort variation
Getting consumables from the sub store etc,
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
8 A
8.2 A
WEAVING MAINTENANCE - MECHANICAL
Proposed Changes & Observations
8.2.2
Use of standard operating procedures
Observations
For the preventive maintenance activities the personnel should use SOP's which
will also detail the time element of the activities to be carried out. Presently
checklists are used, but SOP's will reduce the variations and also act as
benchmarks
Effective supervision
It is observed that the breaks (tea and lunch) taken by the maintenance
personnel are not synchronized and the allowed time / more than the allowed
time for the same is utilized. The maintenance personnel to be trained and
educated that during the preventive maintenance / breakdown maintenance the
times for the breaks can be kept at minimum so that the crew is able to focus
better on the maintenance aspects
Coordination
Coordination between the mechanical and electrical maintenance sections is
poor leading to less effective maintenance levels. On two of the days when the
preventive maintenance activities in the mechanical section were studied it has
been observed that the electrical section did not perform the electrical side of
the preventive maintenance activities. Stopping a particular equipment again
only for electrical maintenance would lead to loss of time and effort
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
8 A
8.3 A
S.No
1
2
3 AIRJET WGM/MECH/03
WEAVING MAINTENANCE - MECHANICAL
DORNIER
SULTEX AND
PICANOL
WGM/MECH/01
WGM/MECH/02
Workload Sheets Summary
WLS Number Area of work
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 2
Designation Proposed Manpower - - - 2
Sl.
No
Crew
Size
Freq/
Year
Basic
Time
(Hrs) -
man
hrs
Total
Time
(Hrs)
1
1.1 2 1040 1.87 1943.26
1.2 2 40 2.22 88.70
1.3 370.59
2
1.1 2 72 2.46 177.32
1.2 2 6 4.63 27.76
A 2607.63
B 15
C 2943.18
D 3840
E 76.65%
F 2
G 76.65%
Activity Description
1. Available man hours per year has been calculated @ 25 working days per month
Yearly maintenance
Net Available man-hrs per year
Present Utilisation(%)
Proposed Manpower per shift
B C G
Mechanical
Sultex (number of machines - 40)
Rest & Relaxation Allowances ( % )
Total Workload ( in man hours per year)
WLS No: WGM/MECH/01
WORK LOAD DETAILS SHEET
Weaving Maintenance
Shifts A
Half yearly maintenance
Sultex and Picanol
Fitter
Remarks:
Proposed Utilisation(%)
Breakdown maintenance
2. The crew size for breakdown maintenance is as per the requirement. We have only considered the
man hrs required for the performance of the activity
Picanol (number of machines - 6)
Monthly maintenance
Yearly maintenance
Basic Workload per Shift ( in man minutes)
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 2
Designation Proposed Manpower - - - 2
Sl.
No
Crew
Size
Freq/
Year
Basic
Time
(Hrs) -
man
hrs
Total
Time
(Hrs)
1
1.1 2 48 11.68 560.56
1.2 2 999.79
A 1560.35
B 15
C 1644.43
D 3840
E 42.82%
F 2
G 42.82%
2. The crew size for breakdown maintenance is as per the requirement. We have only considered the
man hrs required for the performance of the activity
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Remarks:
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man hours per year)
Net Available man-hrs per year
1. Available man hours per year has been calculated @ 25 working days per month
Yearly maintenance
Breakdown maintenance
Dornier
Fitter
Activity Description
Dornier (number of machines - 48)
WLS No: WGM/MECH/02
WORK LOAD DETAILS SHEET
Weaving Maintenance
Shifts A B C G
Mechanical
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 1
Designation Proposed Manpower - - - 2
Sl.
No
Crew
Size
Freq/
Year
Basic
Time
(Hrs) -
Total
Time
(Hrs)
1
1.1 1 52 4.73 245.98
1.2 2 80 4.97 397.83
1.3 2 40 10.05 402.09
1.4 277.86
A 1323.76
B 15
C 1480.64
D 1920
E 77.12%
F 2
G 38.56%
1. Available man hours per year has been calculated @ 25 working days per month
Weekly greasing
2. The crew size for breakdown maintenance is as per the requirement. We have only considered the
man hrs required for the performance of the activity
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Remarks:
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man hours per year)
Airjet
Fitter
Activity Description
Airjet (number of machines - 40)
Net Available man-hrs per year
Half Yearly maintenance
Yearly maintenance
Breakdown maintenance
WLS No: WGM/MECH/03
WORK LOAD DETAILS SHEET
Weaving Maintenance
Shifts A B C G
Mechanical
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
8 B. WEAVING MAINTENANCE - ELECTRICAL
MAINTENANCE
________________________________________________________________________________________
National Productivity Council, Bangalore.
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___________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
8.0 B
8.1 B
I II III G T I II III G T
1 Shift maintenance Electrician 1 1 1 - 3 1 1 1 - 3
2
General shift
maintenance - attending
to major breakdowns and
preventive maintenance
Electrician - - - 3 3 - - - 2 2
3 Humidity plant Humidity attendant 1 1 1 - 3 1 1 1 - 3
4 Engineering Workshop Fitter / Turner - - - 2 2 - - - 1 1
5 Motor maintenance Motor Fitter - - - 1 1 - - - 1 1
6 Motor winding Motor winder - - - 1 1 - - - 1 1
7
Lighting and outside
works
Wireman - - - 2 2 - - - 2 2
8
Cleaning of return air
grills, ducts and RA wire
mesh
Cleaners - - - 3 3 1 1 1 - 3
Total 2 2 2 12 18 3 3 3 7 16
S. No Section / Work area Designation
Present Manpower
Manpower Deployment
WEAVING MAINTENANCE - ELECTRICAL MAINTENANCE
Proposed Manpower
Remarks
_________________________________________________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
8 B
8.2 B
8.2.1 B
a)
b)
8.2.2 B
The start and end times for both the preventive maintenance and the breakdown
maintenance to be maintained. This would help in the analysis of the breakdowns and
in maintenance planning
Use of standard operating procedures
For the preventive maintenance activities the personnel should use SOP's which will
also detail the time element of the activities to be carried out. Presently checklists are
used, but SOP's will reduce the variations and also act as benchmarks. It has also been
observed that the crew use the mobile torch during the maintenance activities which is
not a healthy practice.
Effective supervision
It is observed that the breaks (tea and lunch) taken by the maintenance personnel are
not synchronized and the allowed time / more than the allowed time for the same is
utilized. The maintenance personnel to be trained and educated that during the
preventive maintenance / breakdown maintenance the times for the breaks can be kept
at minimum so that the crew is able to focus better on the maintenance aspects
Coordination
Coordination between the mechanical and electrical maintenance sections is poor
leading to less effective maintenance levels. On two of the days when the preventive
maintenance activities in the mechanical section were studied it has been observed that
the electrical section did not perform the electrical side of the preventive maintenance
activities. Stopping a particular equipment again only for electrical maintenance would
lead to loss of time and effort
WEAVING MAINTENANCE - ELECTRICAL
Proposed Changes & Observations
Deploy two electricians in the general shift for the attending of the preventive
maintenance and breakdown maintenance works instead of the present deployment of
three personnel in the general shift. The utilization is 48 % at 80 % loading factor.
Proposed Changes
Records keeping
Observations
Deploy one person in the workshop instead of the present deployment of two
personnel.
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
8 B
8.2 B
WEAVING MAINTENANCE - ELECTRICAL
Proposed Changes & Observations
8.2.2 B
The activities to be so planned and peformed that the time taken is minimized.
Activites that can be carried out in parallel have to be planned. For example, when the
production personnel are shutting down the machine and handing over for production,
the maintenance personnel can start their activities such as keeping the grease gun
ready, bring all the tools, arrange in the workplace, bring the bearings and other
consumables which are likely to be changed and keep ready in the workplace. It is
observed that the personnel keep making rounds to the workshop often to get tools,
bearings etc,.
Planning
Observations
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
8 B
8.3 B
S.No
1
2
3
4
5
6
7
8
WLS Number Area of work
Humidity plant operator WGM/ELE/08
Workshop fitter and turner WGM/ELE/07
Cleaners WGM/ELE/05
Lighting electricians WGM/ELE/06
Motor Fitter WGM/ELE/03
Motor winder WGM/ELE/04
WEAVING MAINTENANCE
General shift electricians
Shift Electricians WGM/ELE/01
WGM/ELE/02
Workload Sheets Summary
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 1 1 1 -
Designation Proposed Manpower 1 1 1 -
1
2
Date Total time
1-Dec 345
2-Dec 525
3-Dec 445
4-Dec 490
5-Dec 300
6-Dec 395
7-Dec 495
2995
3
4
5
6
/ = 0.2976 ~ 0.30
For / = 0.30 we find that the utilization of the shift electrician is 30 % only per shift.
Hence it is recommended that the deployment of one per shift may be continued and
additional works as deemed fit may be allocated to the incumbent whenever required
The average time to resolve a complaint works out to be 50 minutes and as per the time
distribution also the modal value is 45 minutes.
9
7
8
11
Number of complaints
7
Loomshed
Electrician
Data provided for the period december 1-7 (7 days)
Number of complaints attended on each day and the total time spent for the same is
60
The average arrival rate is 60/7 = 8.57 per day and the average servicing rate =
24*60/50 = 28.8 per day
9
9
WLS No: WGM/ELE/01
WORK LOAD DETAILS SHEET
Weaving Maintenance
Shifts A B C G
Electrical
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 3
Designation Proposed Manpower - - - 2
1
2
3
4
5
PF CE PH CH
SULTEX 75.8 221.0 0.0 1.2
PF
CE
AIR JET 67.8 247.8 0.0 2.2
PH
CH
DORNIER 44.0 140.0 48.0 24.0
PICNOL 126.0 258.0 0.0 0.0
WARPING 27.0 224.0 0.0 17.0
H PLANT 120 * 0.0 0.0 360**
STABILIZER 3.2 9.0 0.0 0.0
TRANSFORMER 1.6 4.0 0.0 0.5
COMPRESSOR 153.5 36.5 0.0 307 **
BREAKDOWN
MAINTENANCE
128.0 702.0 0.0 38.5
TOTAL 506.9 1842.3 48.0 82.2
*
**
Loomshed
Electrician
Contract
Electrician
Permanent
The yearly workload section wise is detailed below:
The preventive maintenance data was collected for all the category of machines. Check studies
on a sample basis were carried out to ascertain the process being followed for the preventive
maintenance.
Detailed discussions were held with the incumbents and the supervisory personnel.
Breakdown maintenance data has been obtained for a period of two months and the same has
been extrapolated for a year.
The sum of the preventive maintenance and the breakdown maintenance workload for the year
gives us the total workload for the general shift electricians. The works performed by the
Motor Fitter, humidity plant operator and the cleaning personnel are refle
WLS No: WGM/ELE/02
WORK LOAD DETAILS SHEET
Weaving Maintenance
Shifts A B C G
Electrical
Section
Included in the Motor Fitter workload and given in the separate workload
sheet
The cleaning personnel workload sheet detailes these activities. Hence the
total not considered here
Yearly Workload of Crew Category Involved (In hrs)
Permanent
Fitter
Contract
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 3
Designation Proposed Manpower - - - 2
Loomshed
Electrician
WLS No: WGM/ELE/02
WORK LOAD DETAILS SHEET
Weaving Maintenance
Shifts A B C G
Electrical
6
-
-
-
-
Collection & deposit of tools, dress change
Effort variation
For the two personnel recommended, the workload percentage appears to be 48 %. Two
personnel are recommended as the base crew size for this kind of maintenance activity is
two personnel
The yearly workload for the personnel works out to be 1842.3 hrs.
The manpower has been computed with a loading factor of 80 % for the maintenance
personnel. The 80 % loading has been considered to take into account the following
Variation in machine availability
Getting consumables from the sub store etc,
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 1
Designation Proposed Manpower - - - 1
1
2
3
4
5
S.No
1
2
6
WLS No: WGM/ELE/03
WORK LOAD DETAILS SHEET
Weaving Maintenance
Shifts A B C G
Electrical
Breakdown maintenance data has been obtained for a period of two months and the same has
been extrapolated for a year.
The sum of the preventive maintenance and the breakdown maintenance workload for the year
gives us the total workload for the general shift electricians. The works performed by the Motor
Fitter are reflected in this worklaod sheet.
The yearly workload for the Motor Fitter, section wise is detailed below:
Loomshed
Motor Fitter
The preventive maintenance data was collected for all the category of machines. Check studies
on a sample basis were carried out to ascertain the process being followed for the preventive
maintenance.
Detailed discussions were held with the incumbents and the supervisory personnel.
Description
For the one person recommended, the workload percentage appears to be 53.48 % (at 80 %
loading)
Workload per
year (Hrs)
The yearly workload for the personnel works out to be 1026.9 hrs.
626.9 Preventive and breakdown maintenance
Check all the motors in the loomshed, clean,
check earthing points, leakage etc.,
Total workload per year
400
1026.9
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 1
Designation Proposed Manpower - - - 1
Sl.
No
Crew
Size
Freq/
Year
Basic
Time -
man
hrs
Total
Time
(Hrs)
1
1 40 2.0 80.00
1 4 4.0 16.00
1 28 12.0 336.00
A 432.00
B 15
C 496.80
D 2400
E 20.70%
F 1
G 20.70%
Activity Description
Rewind the motors of the following categories, check its
performance
WLS No: WGM/ELE/04
WORK LOAD DETAILS SHEET
Weaving Maintenance
Shifts A B C G
Electrical
Net Available man-hrs per year
1 HP and Less
Between 1 HP to 7.5 HP
Above 7.5 HP
Motor Rewinding
Motor Rewinder
1. Man hours per year has been calculated @ 25 working days per month
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man hours per year)
2. The number of the motors serviced and rewinded have been obtained from the present
incumbent.
3. The utilization per year is 20.70 %. As this position has been filled recently, the company will
have to decide the continuity of this position based on the work which will be performed by this
position holder in the next one year. Also the pros and cons of sending the motors for outside
servicing and the advantages of an in house facility for this activity will have to be taken into
consideration by the company.
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Remarks:
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 3
Designation
Proposed
Manpower
1 1 1 -
Sl.
No
C
r
e
w

S
i
z
e
F
r
e
q
/

Y
e
a
r
B
a
s
i
c

T
i
m
e


-

m
a
n

m
i
n
s
T
o
t
a
l

T
i
m
e

(
H
r
s
)
1
a)
1 300 22.10 110.50
b) 1 1095 22.95 418.84
c) 1 300 3.83 19.13
d)
1 1095 38.25 698.06
e) 1 1095 2.55 46.54
f)
1 300 17.14 85.72
g)
1 300 14.03 70.13
h)
2 1095 25.50 930.75
i)
2 1095 51.00 1861.50
j)
1 1095 14.80 270.10
k)
1 1095 26.40 481.80
2
307 **
3
360**
4
82.17
A 5075.23
B 14
C 5785.76
D 8760
E 66.05%
F 1
G 66.05%
Half Trenches inside the loomshed (two numbers - sultex
and picanol area)
Galleries and rooms (3 numbers) above warping
Galleries and rooms (2 numbers) near the electrical
manager's room
Compressors (three numbers)
H plant
Trenches inside the loomshed (two numbers - dornier
area)
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man hours per year)
Net Available man-hrs per year
Battery room (inside grey checking)
Preventive and breakdown maintenance
Main Trenches below the weaving loomshed (7 channels)
Transfer the waste to the waste yard
Weaving power house by broomstick, equipments and
control panel by weaving waste
Work shop
Loomshed
Helpers
Activity Description
Clean the
Manager's room, steps in the department, weft godown,
humidity room near warping, electrical panel room in
warping, yarn godown no 2, collect waste in poly cover
and dispose in the dust bin
Humidity room adjacent to the sultex area
WLS No: WGM/ELE/05
WORK LOAD DETAILS SHEET
Weaving Maintenance
Shifts A B C G
Electrical
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 3
Designation
Proposed
Manpower
1 1 1 -
Sl.
No
C
r
e
w

S
i
z
e
F
r
e
q
/

Y
e
a
r
B
a
s
i
c

T
i
m
e


-

m
a
n

m
i
n
s
T
o
t
a
l

T
i
m
e

(
H
r
s
)
Loomshed
Helpers
Activity Description
WLS No: WGM/ELE/05
WORK LOAD DETAILS SHEET
Weaving Maintenance
Shifts A B C G
Electrical
1. Man hours per year has been calculated @ 25 working days per month
2. Presently three personnel are working in the general shift, but discussions with the manager has
revealed that they would be deployed in the shifts after the training period
3. The time taken for the activities will be less than what is reflected here as the cleaning will be
taking place in all the shifts and not in general shift as at present. This will impact activites g,h,i,j,k
Remarks:
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 2
Designation Proposed Manpower - - - 2
Sl.
No
Crew
Size
Freq/
Day
Basic
Time -
man
mins
Total
Time
(mins)
1 1 1 30.00 30.00
2 1 1 60.00 60.00
3 2 5 48.00 480.00
A 510.00
B 15
C 586.50
D 960
E 61.09%
F 2
G 61.09%
WLS No: WGM/ELE/06
WORK LOAD DETAILS SHEET
Weaving Maintenance
Shifts A B C G
Electrical
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Daily check the tubelights in mending, loom shed,warping
and drawing * 2
Attend to complaints in the various departments
Loomshed & outside
Electricians
Activity Description
KWH meter reading
3. This crew has attended 31 complaints in 7 days (29th dec - jan 4th), the data for which was
provided. The average number of complaints handled is ranging between 4 -5 per day with an
average handling time of 48 minutes.
Proposed Utilisation(%)
Remarks:
1. Man hours per year has been calculated @ 25 working days per month
2. During the studies in the various departments this activity by the electrical staff has not been
observed regularly and this actiivty does not add value. Hence this activity time is not included in
the total. Whenever there is a complaint then the same may be resolved by the deployed crew.
Total Workload ( in man hours per day)
Net Available man-hrs per day
Present Utilisation(%)
Proposed Manpower per shift
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 2
Designation Proposed Manpower - - - 1
1
2
3
4
5
During the observations carried out, it has been observed that the primary work is performed
by the personnel who need the work to be carried out (various maintenance departments). The
workshop personnel only perform secondary works such as providing technical assistance in
the completion of the works.
The works being carried out in this department is not very complex and the equipment is very
old and not very high precision type.
Keeping in mind the above points, it is recommended that the workshop be manned by one
person.
Workshop
Fitter / Turner
The following equipment are present in the workshop: 2 lathes, 1 shaper, 1 planer, and 1
power hacksaw. All the equipment are very old and the planer in fact is 1899 make model.
Detailed discussions were held with the incumbents and the supervisory personnel.
WLS No: WGM/ELE/07
WORK LOAD DETAILS SHEET
Weaving Maintenance
Shifts A B C G
Electrical
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 1 1 1 -
Designation Proposed Manpower 1 1 1 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time -
man
mins
Total
Time
(mins)
1 1 1 30.00 30.00
2
a) 1 1 15.00 15.00
b) 1 1 30.00 30.00
c) 1 1 90.00 90.00
d) 1 1 10.00 10.00
e) 1 1/18 90.00 5.00
f) 1 1/60 300.00 5.00
3 1 4 10.00 40.00
4
1 2/3 45.00 30.00
A 255.00
B 15
C 293.25
D 450
E 65.17%
F 1
G 65.17%
Once in two hours record readings from the 6
thermometers
Operate valves, perform back wash
Operate the softner plant
Perform flashing
Operate the RO plant
Clean plant premises
Proposed Manpower per shift
Proposed Utilisation(%)
Remarks:
Basic Workload per Shift ( in man minutes)
Nozzle cleaning (performed only during the A and B
Clean the nozzles: during summer one hour spent on this
activity (about 4 in sultex and 3 in others) and during
winter 30 minutes spent on this activity (about 2 in sultex
and 2 in others). Hence taken 50 % @ 1 hour and 50 % @
30 minutes
Net Available man-hrs per day
Present Utilisation(%)
Humidity plant
H plant operator
Activity Description
Check all the supply air fans ( 19 numbers) and return air
fans (13 numbers) and pumps (12 numbers) for the 7
plants daily
Rest & Relaxation Allowances ( % )
Total Workload ( in man hours per day)
Clean the 6 filters in RO plant once in a week
Change salt every 20 days (70 Kg)
WLS No: WGM/ELE/08
WORK LOAD DETAILS SHEET
Weaving Maintenance
Shifts A B C G
Electrical
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
9. WEAVING - QA
________________________________________________________________________________________
National Productivity Council, Bangalore.
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___________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
9.0
9.1
I II III G T I II III G T
1 Greige fabric checking Investigator / Checker - - - 1 1 - - - 1 1
Helper - - - 1 1 - - - 1 1
2 Weaving QA Investigator 1 1 1* - 2 1 1 - - 2
* Staff category and
the rest are contract
employees
3 QA - Process Lab Investigator 1 1 1 - 3 1 1 1 - 3
Total 2 2 1 2 7 2 2 1 2 7
S. No Section / Work area Designation
Present Manpower
Manpower Deployment
WEAVING - QA
Proposed Manpower
Remarks
_________________________________________________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
9.0
9.2
9.2.1
a)
WEAVING - QA
Proposed Changes & Observations
Proposed Changes
No changes proposed.
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
9.0
9.3
S.No
1
2
3
WEAVING - QA
Quality rounds and report preparation
Process lab WGQA/03
Checking of fabric received from the
outside vendors
WGQA/01
WGQA/02
Workload Sheets Summary
WLS Number Area of work
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 2
Designation Proposed Manpower - - - 2
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
2 14 0.64 18.02
2 1 18 7.12 128.16
3
1 18 0.63 11.25
4
1 36 0.48 17.28
5 2 18 0.27 9.60
6 1 18 0.27 4.80
7
1 9 0.45 4.05
8
2 4 7.32 58.56
9 2 4 3.30 26.40
10
2 4 1.71 13.65
11
2 1 30.00 60.00
12 1 4 8.20 32.80
13
1 18 1.50 27.00
A 411.58
B 17
C 481.54
D 960
E 50.16%
F 2
G 50.16%
2. The inspection will be carried out in cycles of 20 minutes followed by a break of 17 % X 20
minutes = 3.4 minutes. The two personnel will be carrying out the inspection in turns. When one
person avails tea break, the other can continue the inspection .
Write details of completed roll in the record, open new page,
write details of the new roll, set counter to zero
Entry of greige fabric checking in SAP
Remarks:
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Checking of Ends & Picks of the all inspected fabric pieces
Collect the rolls to be processed from the respective storage
areas, weigh and stack near the machine
Transport completed rolls to the big batching machine
Others such as discussion with the superiors, getting
instructions etc,.
Write quality details on the fabric - twice
Untie knots, keep the completed roll in the designated area
Load new empty spindle, roll certain length of cloth
Cut cloth piece at the end
1. The average length is considered as 100 meters
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Place new roll on the stand, pull some cloth, tie two ends to
the previous fabric
Inspect fabric till the fabric roll is completed
Greige Fabric Checking
Investigator, Helper
Activity Description
Load new roll in the machine, pass through the rollers, pull
fabric till the inspection table
WLS No: WGQA/01
WORK LOAD DETAILS SHEET
Weaving
Shifts A B C G
Quality Assurance
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 1 1 1* -
Designation Proposed Manpower 1 1 1 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
1.1
1 1 70.71 70.71
1.2
1 3 3.00 9.00
1.3
1 3 1.00 3.00
1.4
1 4 5.00 20.00
2
1 1 25.00 25.00
A 127.71
B 15
C 146.86
D 450
E 32.64%
F 1
G 32.64%
* - Staff category
Rest & Relaxation Allowances ( % )
Ascertain the defects being noticed in the grey checking
machines, note down the quality number and the defect
meters
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Remarks:
WLS No: WGQA/02
WORK LOAD DETAILS SHEET
Weaving
Shifts A
Basic Workload per Shift ( in man minutes)
Quality Assurance
Investigator
Activity Description
Quality round of the loom shed - 134 looms
B C G
Quality Assurance
Net Available man-mins
Input data into the computer, file documents
Check for the quality of the fabric being woven in the
looms, mark defects by chalk
In case of non conformities, discuss with the production
supevisor
Prepare slips for the non-conformity observed and place
one slip in the roll being processed
Total Workload ( in man minutes )
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 1 1 1 -
Designation Proposed Manpower 1 1 1 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
1.1 1 1 26.32 26.32
1.2 1 3 10.23 30.70
1.3
1 1 105.26 105.26
1.4
1 1 21.93 21.93
1.5
1 1 31.14 31.14
1.6 1 1 24.92 24.92
1.7 1 1 62.30 62.30
1.8 1 1 5.00 5.00
2
2.1
1 1 42.10 42.10
2.2
1 3 10.23 30.70
2.3
1 1 31.14 31.14
2.4
1 1 62.30 62.30
2.5
1 1 5.00 5.00
2.6
1 1/9 60.00 6.67
2.7
1 1/6 60.00 10.00
Samples submission to despatch department, bills
collection from HOD office and forwarding to accounts
department
Yarn testing (Blend % & Colour fastness to washing) - 8
samples (1 reading)
Fabric sample collection from Process House - 14 samples
Development fabric testing (Width, GSM, Colour fastness
to washing, water & rubbing, Blend composition & Pilling)
- 5 samples (1 reading)
Outsourced fabric testing-bulk (Colour fastness to washing
& rubbing & Pilling) - 10 samples (1 reading)
Folding of the roll strips for grouping and returning back to
folding department - 60 strips
Material collection from stores (Chemical & stationary for
lab use)
Fibres testing (Colour fastness to washing) - 20 samples
(1 reading)
Sample preparation for CSV checking - 18 samples
(1 reading)
Shift B
Development fabric testing (Width, GSM, Colour fastness
to washing, water & rubbing, Blend composition & Pilling)
- 5 samples (1 reading)
Outsourced fabric testing-preshipment (Width, GSM,
Colour fastness to washing & rubbing, Blend composition,
Pilling) - 4 samples (1 reading)
Outsourced fabric testing-bulk (Colour fastness to washing
& rubbing & Pilling) - 10 samples (1 reading)
Folding of the roll strips for grouping and returning back to
folding department - 60 strips
Process lab
Investigator
Activity Description
Shift A
Instrument & Lab Cleaning
Fabric sample collection from Process House - 14 samples
WLS No: WGQA/03
WORK LOAD DETAILS SHEET
Weaving
Shifts A B C G
Quality Assurance
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 1 1 1 -
Designation Proposed Manpower 1 1 1 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
Process lab
Investigator
Activity Description
WLS No: WGQA/03
WORK LOAD DETAILS SHEET
Weaving
Shifts A B C G
Quality Assurance
3
3.1 1 3 10.23 30.70
3.2
1 1 18.69 18.69
3.3
1 1 124.60 124.60
A 669.47
B 14
C 763.20
D 1350
E 56.53%
F 3
G 56.53%
Fabric sample collection from Process House
Shift C
Bulk fabric sample testing-Domestic fabric (Width, Colour
fastness to washing & rubbing & Pilling) - 20 samples (1
reading)
Remarks:
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per day
Proposed Utilisation(%)
Basic Workload per day ( in man minutes)
Bulk fabric sample testing-RMG fabric (Width, GSM,
Colour fastness to washing, water & rubbing, Blend
composition & Pilling, CSV stitching) - 3 samples (1
reading)
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
10. CHECKING, MENDING AND FINISHING
________________________________________________________________________________________
National Productivity Council, Bangalore.
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___________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
10.0
10.1
I II III G T I II III G T
1 Grey checking Checker 4 4 3 - 11 4 4 3 - 11
Loader 6 6 4 - 16 4 4 3 - 11
Segregator cum
Loader
2 3 - - 5 - - - - -
2 Mending Damage reporter - - - 1 1 - - - 1 1
Menders - - - 45 45 - - - 28 28
Mended fabric
checker
- - - 3 3 - - - 4 4
Loaders - - - 3 3 - - - - -
Cleaner - - - 1 1 - - - 1 1
Computer operator 2 - - 1 3 2 - - 1 3
3 Kitty mending Kitty Menders - - - 17 17 - - - 8 8
Totally 20 are there,
17 are in mending
and 3 in finish folding
4 Finish folding Finish Checker - - - 1 1 - - - 1 1
5 Perching Checker 4 4 4 - 12 2 2 2 - 6
6 Fold machine Operator - - - 3 3 - - - 2 2
Helper - - - 3 3 - - - 2 2
7 Grading section Monitor - - - 1 1 - - - 1 1
Sample man - - - 2 2 - - - 2 2
Loader - - - 2 2 - - - 2 2
Grader - - - 25 25 - - - 18 18
THAN loader - - - 2 2 - - - 2 2
S. No Section / Work area Designation
Present Manpower
Manpower Deployment
CHECKING, MENDING AND FINISHING
Proposed Manpower
Remarks
_________________________________________________________________________________________________________________________________
National Productivity Council, Bangalore.
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___________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
10.0
10.1
I II III G T I II III G T
S. No Section / Work area Designation
Present Manpower
Manpower Deployment
CHECKING, MENDING AND FINISHING
Proposed Manpower
Remarks
Cut piece grader - - - 9 9 - - - 7 7
Kitty Menders - - - 3 3 - - - 2 2
8 THAN packing
Bar code sticker
operator
- - - 1 1 - - - 1 1
Manpower
deployment given per
line
Helper - - - 3 3 - - - 3 3
THAN folder - - - 2 2 - - - 2 2 Per line
THAN screening - - - 1 1 - - - 1 1 Per line
THAN stamper - - - 1 1 - - - 1 1 Per line
Wrapper man - - - 1 1 - - - 1 1 Per line
Poly bag man - - - 1 1 - - - 1 1 Per line
THAN segregator - - - 3 3 - - - 3 3
9 PL Packing section PL Packers - - - 16 16 - - - 16 16
FRC Sorter - - - 2 2 - - - 1 1
10 B & R Inspection Finish Checker - - - 1 1 - - - 1 1
Inspector 8 8 8 - 24 7 7 7 - 21
Packers 6 6 4 - 16 4 4 4 - 12
Sample man - - - 1 1 - - - 1 1
11 Finish folding Helper - - - 4 4 - - - 4 4
Computer operator - - - 2 2 - - - 2 2
Cleaner - - - 2 2 - - - 1 1
Total 32 31 23 163 249 23 21 19 121 184
_________________________________________________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
10.0
10.2
10.2.1
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
Fold machines - operate two machines per day to fulfill the production requirements of
26500 per day, hence deploy 4 personnel instead of the present deployment of 6
personnel
THAN grader - deploy eighteen personnel instead of the present deployment of twenty
five per day based on workload
CP grader - deploy seven personnel instead of the present deployment of nine per day
based on workload
Kitty mender in grading - Deploy 2 personnel instead of the present deployment of 3
personnel, based on workload. The graders may be trained in this activity also so that
this position may be eliminated in the long run.
FRC sorter - Deploy 1 person instead of the present deployment of 2 personnel, based
on workload.
CHECKING, MENDING AND FINISHING
Proposed Changes & Observations
Proposed Changes
Mending checker helper - Deploy none as mender helper inspead of the present
deployment os one along with each checker. The utilization amounts to 14.69 % and
these activities may be performed by the mender who takes his fabric for re-inspection.
Kitty mender - Deploy 8 personnel instead of the present deployment of 17 personnel,
based on workload.
Perching - deploy two operators per shift instead of the present deployment of 4 per
shift. The organization needs to operate only two machines per shift
Deploy one personnel for two machine as loaders in the grey checking area instead of
the present deployment of three personnel for two machines. The workload works out to
be 15.28 % per shift per machine. Also the activities of the segregator cum loader are
also to be performed by these loaders. During the inspection of the rolls adequate time
is available to carry out the segregator cum loaders's activities also. At the outset it is
recommended that one person per machine be deployed and thereafter this may be
rationalized to the above staffing pattern after some period of working.
Segregator cum loader - deploy none per shift instead of the present deployment of 2 in
A shift and 3 in the B shift. The activiites will henceforth be performed by the grey
checking loaders. The utilization per shift is 10.29 % for each of the two personnel
deployed.
Menders - Deploy 28 menders in general shift instead of the present deployment of 45
in general shift. An allowance of 17 % has been provided and the personnel may avail
these allowances after the time specified in the workload sheets.
Mender checkers - Deploy 4 personnel in general shift inatead of the present
deployment of three personnel, if all the 9000 meters have to be checked.
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
10.0
10.2
10.2.1
CHECKING, MENDING AND FINISHING
Proposed Changes & Observations
Proposed Changes
m)
n)
o)
B & R inspection - packers - deploy 4 personnel per shift instead of the present
deployment of 6 personnel. The breakup of the activities are explained in detail in the
workload sheet
Finish folding - cleaner - deploy one person in the general shift instead of the present
deployment of two per day based on workload
Rolling cum inspection - Checkers - Operate 7 machines per shift instead of the present
operation of eight machines, hence deploy 7 personnel as checkers instead of the
present deployment of 8 personnel per shift
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
10.0
10.3
S.No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
Cleaner - finish folding
Monitor
Finish checker - B & R section
Bale helpers
Sample man - B & R section
Bar code operator - B & R section
Computer operator - B & R section
THAN segregator
PL packer - bar code operator
PL packer - screening
FRC sorters
Rolling machine inspection B & R
section
Packers - B & R section
Alignment helper
THAN folder
Screening
Stamping
Wrapper man
Poly bag man
THAN grader
Cut piece grader
THAN loader
Kitty mender in grading
Perching checker
Finish fold operator and helper
Sample man
Finish folding loader
Bar code operator
Mender checker helper
Kitty mender
CMF/38
CMF/30
CMF/31
CMF/32
CMF/33
CMF/26
CMF/27
CMF/39
CMF/40
CMF/41
CMF/34
CMF/35
CMF/36
CMF/37
CMF/28
CMF/29
CMF/22
CMF/23
CMF/24
CMF/25
CMF/16
CMF/17
CMF/18
CMF/19
CMF/20
CMF/21
CMF/12
Computer operator - mending
CMF/10
Computer operator - mending
CMF/14
CMF/15
CMF/08
Computer operator - mending
CMF/09
Damage Reporter
CMF/13
CHECKING, MENDING AND FINISHING
Grey checking loader
Cleaner - mending
CMF/11
Finish Checker - finish folding
Segregator cum loader CMF/03
Mender CMF/04
CMF/07
Mender checker CMF/05
CMF/06
Grey Checker CMF/01
CMF/02
Workload Sheets Summary
WLS Number Area of work
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 4 4 3 -
Designation Proposed Manpower 4 4 3 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 20 10.67 213.40
2 1 20 0.63 12.60
3 1 40 0.48 19.20
4 1 1 25.64 25.64
A 270.84
B 17
C 316.88
D 440
E 72.02%
F 1
G 72.02%
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Others such as discussion with the superiors, getting
instructions etc,.
Remarks:
1. The average length is considered as 150 meters
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Inspect fabric till the fabric roll is completed
Write details of completed roll in the record, open new
page, write details of the new roll, set counter to zero
Write quality details on the fabric - twice
Grey Checking
Checker
Activity Description
2. The inspection will be carried out in cycles of 24.52 minutes followed by a break of 17 % X 24.52
minutes = 4.2 minutes. There can be 14 cycles of inspection in the shift, after accounting for 30
minutes of discussions and a tea time of 14.2 minutes. One of the breaks has to be combined with the
time of ten minutes provided to make a tea time of 14.2 minutes. 14 cycles has been calculated based
on 410 minutes ( 450-10 minutes tea - 30 minutes discussions). In each cycle 300 meters of fabric
can be processed
WLS No: CMF/01
WORK LOAD DETAILS SHEET
Checking, Mending
& finishing Shifts A B C G
Grey Checking
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 6 6 4 -
Designation Proposed Manpower 4 4 3 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 2 16 0.46 14.72
2 2 20 0.27 10.67
3 1 20 0.12 2.40
4 1 20 0.27 5.33
5 2 20 0.32 12.98
6 2 4 1.71 13.68
A 59.78
B 15
C 68.75
D 450
E 15.28%
F 4
G 15.28%
Remarks:
1. The average length is considered as 150 meters
Keep the empty roll in the designated area
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Grey Checking
Loader
Activity Description
Place new roll on the stand, pull some cloth, tie two ends to
the previous fabric
Load new roll in the machine, pass through the rollers, pull
fabric till the inspection table
Untie knots, keep the completed roll in the designated area
Load new empty spindle, roll certain length of cloth
Collect the rolls to be processed from the respective
storage areas, weigh and stack near the machine
2. The utilization being 15.28 % for one person, one loader should be able to handle all four
machines, but keeping in mind the interference it is recommended that one loader may be allocated
two machines each. The checker will assist the loader in activities wherein the crew size is two
personnel.In the initial stage one person per machine is recommended,later one person per two
machine could be reached
WLS No: CMF/02
WORK LOAD DETAILS SHEET
Checking, Mending &
finishing Shifts A B C G
Grey Checking
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 2 3 - -
Designation Proposed Manpower - - - -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 2 5 0.69 6.86
2 2 67 0.51 68.34
3 1 5 0.44 2.20
4
5 1 1 10.00 10.00
A 87.40
B 13
C 98.76
D 960
E 10.29%
F -
G -
Remarks:
1. For stacking the rolls the present norm is 4000 meters per person. Since 5 personnel are deployed
per day, 20000 meters has been considered per day. The average roll length is 150 meters, hence
giving us about 134 rolls to be processed per day. Converting this on a per shift basis we get 67 rolls
to be processed per shift.
2. This position is not being recommended. It is suggested that this activity be performed by the
machine loaders.
In case of any problem, reconsile
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Grey Checking
Segregator cum Loader
Activity Description
Transport rolls from the grey checking machines to work
area
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Stack the rolls as per the sequence, note details in the
register
Move the empty trolley back to grey checking area
Send recorded figure in the register to the computer
WLS No: CMF/03
WORK LOAD DETAILS SHEET
Checking, Mending &
Shifts A B C G
Grey Checking
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 45
Designation Proposed Manpower - - - 28
Sl.
No
Crew
Size
Freq/
Shift
(meters)
Basic
Time
(Mins)
Total
Time
(Mins)
1
1 9000 1.00 9000.00
2
1 60 3.49 209.23
3
1 60 1.00 60.00
4
1 9000 0.18 1620.00
5
1 60 1.04 62
A 10951.63
B 17
C 12813.41
D 480
E 59.32%
F 28
G 95.34%
Time in minutes per
meter
Weight
ed
average
0.16 0.04
0.36 0.09
0.963 0.24
2.52 0.63
1.00
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Category
Total Workload ( in man minutes )
1
Weight
25%
Proposed Utilisation(%)
Remarks:
1. The time of one minute per meter of fabric has been arrived at after studying the various categories
of the fabric being mended and based on the time taken for each of these categories. Based on the
discussions with the various personnel it was decided to allocate 25 % weightage to each of the four
categories. The weighted average time per meter is 60 seconds ~ 1 minute. If the weights are going to
change in the future then the weighted average time also will be changing.
2
3
4
25%
25%
25%
Mending
Mender
Activity Description
Put the piece on the mending table for mending, rectify
the defects if found on the mending table, put flag on
unmendable defects
Weighted average time in minutes per meter
Collect fabric in trolley, transport trolley to the rerolling
machine / mending checker and back to work place
Transport the 'to be processed material' near the work
place and reposition trollies after completion
Check the fabric along with the mended fabric checker
Reposition trollies, tie knots to the fabric and push
fabric in the bin
WLS No: CMF/04
WORK LOAD DETAILS SHEET
Checking, Mending &
finishing
Shifts A B C G
Mending
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 3
Designation Proposed Manpower - - - 4
Sl.
No
Crew
Size
Freq/
Shift
(meters)
Basic
Time
(Mins)
Total
Time
(Mins)
1
2
A 1593.00
B 17
C 1863.81
D 480
E 129.43%
F 4
G 97.07%
Total Workload ( in man minutes )
Remarks:
1. The time of one minute per meter of fabric has been arrived at after studying the various categories
of the fabric being mended and based on the time taken for each of these categories.
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
1 9000
Basic Workload per Shift ( in man minutes)
0.18
Rest & Relaxation Allowances ( % )
1593
Mending
Mender Checker
Activity Description
Check the fabric along with the mender, get mendable
defects corrected by the mender
Record the details of the fabric checked and send to the
computer operator
WLS No: CMF/05
WORK LOAD DETAILS SHEET
Checking, Mending
& finishing
Shifts A B C G
Mending
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 3
Designation Proposed Manpower - - - -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
1 60 1.04 62
A 62.40
B 13
C 70.51
D 480
E 14.69%
F -
G -
Total Workload ( in man minutes )
Remarks:
1. This activity may be performed by the mender who brings his fabric for checking. This is being
shifted to the corresponding workload sheet.
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Mending
Mender Helepr
Activity Description
Reposition trollies, tie knots to the fabric and push
fabric in the bin
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
WLS No: CMF/06
WORK LOAD DETAILS SHEET
Checking, Mending &
finishing
Shifts A B C G
Mending
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 17
Designation Proposed Manpower - - - 8
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
2 23 0.97 44.62
2
2 1020 2.59 2641.80
A 2686.42
B 17
C 3143.11
D 480
E 38.52%
F 8
G 81.85%
Time in man-minutes
per meter
Weighte
d
average
0.67 0.17
1.95 0.49
2.46 0.62
5.28 1.32
2.59
2 25%
Weighted average time in minutes per meter
2. Four groups of two personnel each are being recommended.
3 25%
4 25%
Proposed Utilisation(%)
Remarks:
1. The time of one minute per meter of fabric has been arrived at after studying the various
categories of the fabric being kitty mended and based on the time taken for each of these categories.
Based on the discussions with the various personnel it was decided to allocate 25 % weightage to
each of the four categorie. The weighted average time per meter is 2.59 man-minutes per meter. If the
weights are going to change in the future then the weighted average time also will be changing.
Category Weight
1 25%
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Check and remove the superficial defects in the fabric
after observing the singeing and finish fabrics
Kitty Mending
Kitty Mender
Activity Description
Load new fabric roll, reposition trollies
WLS No: CMF/07
WORK LOAD DETAILS SHEET
Checking, Mending &
finishing
Shifts A B C G
Mending
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 1
Designation Proposed Manpower - - - 1
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
1 1 30.00 30.00
2
1 1 60.00 60.00
3
1 1 60.00 60.00
4
1 1 15.00 15.00
A 165.00
B 15
C 189.75
D 480
E 39.53%
F 1
G 39.53%
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Based on the feedback of the menders, inspect the piece,
call the concerned supervisor of weaving, discuss with
him enter details in the register
Proposed Utilisation(%)
Remarks:
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Mending
Damage Reporter
Activity Description
Distribute the fabric after grey checking and make
entries in the allocation register
Enter details mender-wise in the mender's production
register
Based on the feedback of the menders, inspect the piece,
call the concerned supervisor of spinning, discuss with
him enter details in the register
WLS No: CMF/08
WORK LOAD DETAILS SHEET
Checking, Mending &
finishing
Shifts A B C G
Mending
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 1
Designation Proposed Manpower - - - 1
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 1 17.54 17.54
2 1 1 39.47 39.47
3 1 1 26.32 26.32
4 1 1 13.16 13.16
5 1 1 13.16 13.16
6 1 1/2 13.16 6.58
7 1 1 19.74 19.74
8 1 1 26.32 26.32
9 1 1 10.00 10.00
Calculate 'upto date' and 'daily' production for loomshed
in SAP and export data to excel to prepare 'khata wise
daily grey checking report'
Calculate the stock pending in the mending from SAP
and convert to excel
Perform loom out after the completion of the grey
checking, mending and mending checking
Make entry from the menders production register to
excel sheet and once in 15 days calcualte the quantum of
work completed using calculator and record the same in
register
Manually enter the number of personnel present after
checking, in a printed format, check with the deposited
cards, & for people who are on OT make entry in the
OT register. Prepare OT list, send to time office. Get the
'daily present employee list for the date' every 2-3 days
from the time office and verify with manually entered
data in OT register. In case of any deviations in the list,
go to the time office and clarify. Get sign of the section
head and the departmental head on the 'daily present
employee list for the date' and submit to time office
Enter leave details in the register and submit the forms
to time office
Mending
Computer operator
Activity Description
Mark attendance for all workmen (77 in mending and 24
in grey checking)
For material going out for mending, prepare challan sub-
contractor wise. Compute the total per day per worker
employed and check whether it matches with 4000
meters
Prepare loomwise major damage report
WLS No: CMF/09
WORK LOAD DETAILS SHEET
Checking, Mending &
finishing Shifts A B C G
Mending
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 1
Designation Proposed Manpower - - - 1
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
Mending
Computer operator
Activity Description
WLS No: CMF/09
WORK LOAD DETAILS SHEET
Checking, Mending &
finishing Shifts A B C G
Mending
10 1 1/7 120.00 17.14
A 189.42
B 15
C 217.84
D 480
E 45.38%
F 1
G 45.38%
Proposed Manpower per shift
Proposed Utilisation(%)
Remarks:
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Basic Workload per Shift ( in man minutes)
Prepare special reports as per the instructions of the
HOD
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 1 - - -
Designation Proposed Manpower 1 - - -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 276 0.31 84.64
2 1 1 13.50 13.50
3 1 1 15.00 15.00
4 1 1 13.16 13.16
5 1 1 13.50 13.50
6 1 1 10.00 10.00
7 1 1/7 120.00 17.14
A 166.94
B 13
C 188.64
D 450
E 41.92%
F 1
G 41.92%
Prepare special reports as per the instructions of the HOD
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Remarks:
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Mending
Computer operator
Activity Description
Enter grey checking report in SAP for all 3 shifts (276 per
day) (quality, meter and weight)
Make entries of the checkers in SAP
Input piece number and code number of menders in SAP from
the allocation register and after completion of works, enter
details in SAP
Input piece number and code number for material being sent
out for mending in SAP
Prepare loom damage report from grey checking report
When the mended material returns from the sub-contractor,
make necessary entries in SAP
WLS No: CMF/10
WORK LOAD DETAILS SHEET
Checking, Mending &
finishing
Shifts A B C G
Mending
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 1
Designation Proposed Manpower - - - 1
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 276 0.46 126.91
2 1 1 40.00 40.00
3 1 1 15.00 15.00
4 1 1 15.00 15.00
5 1 1/7 120.00 17.14
A 214.06
B 13
C 241.88
D 480
E 50.39%
F 1
G 50.39%
1. For both the compter operators put together the utilization is 90 %. Once computer operator is
recommended in the general shift.
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Rest & Relaxation Allowances ( % )
Prepare 'summary of non-compliance pieces from
01.01.2012 onwards', in excel
For a particular quality number, if the defects are more then
take out the particular grey checking report, based on the
instructions of the superiors
Receive 'off standard card' from weaving production, enter
the piece number and meters and hand over to quality
control
Proposed Utilisation(%)
Remarks:
Mending
Computer operator
Activity Description
Enter grey checking report in SAP for all 3 shifts (276 per
day) (defects details)
Prepare special reports as per the instructions of the HOD
Basic Workload per Shift ( in man minutes)
WLS No: CMF/11
WORK LOAD DETAILS SHEET
Checking, Mending &
finishing
Shifts A B C G
Mending
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 1 - - -
Designation Proposed Manpower 1 - - -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 1 85.03 85.03
2 1 1 81.40 81.40
3 1 1 3.00 3.00
A 169.43
B 13
C 191.46
D 450
E 42.55%
F 1
G 42.55%
WLS No: CMF/12
WORK LOAD DETAILS SHEET
Checking, Mending &
finishing
Shifts A
Cleaner
Activity Description
Clean with broom stick the mending and grey checking
area
B
Collect dust and waste in the polythene covers and
tranfer to the waste yard
Present Utilisation(%)
Proposed Manpower per shift
Mending
Proposed Utilisation(%)
C G
Mending
Remarks:
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Net Available man-mins
Clean with mop the mending and the grey checking
areas
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 1
Designation Proposed Manpower - - - 1
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 1 45.00 45.00
a)
b)
c)
2 1 1 30.00 30.00
3 1 1 10.00 10.00
4 1 1 60.00 60.00
5 1 1 15.00 15.00
A 160.00
B 15
C 184.00
D 480
E 38.33%
F 1
G 38.33%
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Proposed Utilisation(%)
Remarks:
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Measure the cut pieces cut by graders
Reverse fold (place yellow strip inside)
Direct fold (green slip)
Reject slip
Match the samples with the process house materials
Finish Folding
Finish Checker
Activity Description
Check the process batch card for QC approval. If
approved, then make entries in the register for
qualititeswhich are to be sent for
In the direct fold machine check the length and in case
of any problem, get it rectified by the fitter
Enter details of the data written in the register into excel
sheet. Take out printout. Send the data regarding the
pieces packed to marketing department who in turn
provide information regarding the assortment to be
carried out.
WLS No: CMF/13
WORK LOAD DETAILS SHEET
Checking, Mending
& finishing
Shifts A B C G
Finish Folding
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 4 4 4 -
Designation Proposed Manpower 2 2 2 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 60 1.08 64.64
2 1 60 0.29 17.28
3 1 60 7.35 441.00
4 1 6 2.32 13.92
5 1 10 0.80 8.00
6 1 10 1.60 16.00
A 560.84
B 17
C 656.18
D 440
E 37.28%
F 2
G 74.57%
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
2. For a production of 6000 meters per shift, two machines need to be operated and hence two
operators per shift are being recommended
3. The inspection will be carried out in cycles of 17.44 minutes followed by a break of 17 % X 17.44
minutes = 3.0 minutes. There can be 20 cycles of inspection in the shift, after accounting for 15
minutes of discussions and a tea time of 13.0 minutes. One of the breaks has to be combined with the
time of ten minutes provided to make a tea time of 13.0 minutes. 20 cycles has been calculated based
on 425 minutes ( 450-10 minutes tea - 15 minutes discussions). Each cycle 200 meters of fabric can
be processed.
Proposed Utilisation(%)
Remarks:
1. Each roll is 100 meters and the processing is 6000 meters per shift
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Transport empty horse to the process house, check
materials on new horse, and transport the new horse to
the perching machine
Insert new tag cartridge
Transport completed trolley to the next work station
and bring back empty trolley and position
Perching
Perching Checker
Activity Description
Tag at four places and affect changeover
Reset meter and start new page
Perform checking, insert tag whereever required, note
details in the register
WLS No: CMF/14
WORK LOAD DETAILS SHEET
Checking, Mending &
finishing Shifts A B C G
Finish Folding
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 6 6 6 -
Designation Proposed Manpower 4 4 4 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 2 27 0.99 53.64
2 1 27 0.20 5.40
3 1 27 1.59 42.84
4 1 265 2.09 553.85
5
6
7 1 265 1.48 392.20
8 1 265 0.48 125.88
9 1 265 0.21 56.31
A 1396.89
B 14
C 1592.46
D 480
E 331.76%
F 4
G 82.94%
Pull fabric from the fold machine onto work table
Perform counting
2 265 0.31
Position trolley, load fabric onto it
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
2. Two machines per shift need to be operated to fulfill the production requirements of 26500 meters
per day.
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Remarks:
1. Folding time and checking time is for 100 meters
C G
Finish Folding
166.77
Proposed Utilisation(%)
Scrutinize papers
Pull fabric into the machine, adjust
Start folding
Push completed onto work table and tear fabric
Write details on fabric, paper
Finish folding
Operator
Activity Description
Position perching trolley
WLS No: CMF/15
WORK LOAD DETAILS SHEET
Checking, Mending &
finishing
Shifts A B
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 2
Designation Proposed Manpower - - - 2
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 200 0.82 164.00
2 1 200 0.25 50.00
3 1 200 0.99 197.50
4 1 200 0.56 112.00
5 1 200 0.75 150.00
6 1 30.00 30.00
A 703.50
B 14
C 801.99
D 480
E 83.54%
F 2
G 83.54%
Grading
Sample man
Activity Description
Cut sample cloth, write number on cloth, keep aside,
arrange, compare with assorted grey card
WLS No: CMF/16
WORK LOAD DETAILS SHEET
Checking, Mending &
finishing
Shifts A B C G
Finish Folding
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Clarify shade number to the next section personnel
Paste the sample fabric in the sample book
Print out bar code stickers, stick and tag
Deliver sample fabric to warehouse
Maintain sample book of production, marketing and
ware house seperately
Remarks:
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 2
Designation Proposed Manpower - - - 2
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 265 0.21 56.31
2 1 150 1.91 285.75
A 342.06
B 14
C 389.95
D 480
E 40.62%
F 1
G 81.24%
C G
Finish Folding
Grading
Loader
Activity Description
Assist folding helper to load fabric to the trolley
WLS No: CMF/17
WORK LOAD DETAILS SHEET
Checking, Mending &
finishing
Shifts A B
Total Workload ( in man minutes )
Shift double folded fabric to the graders, write piece
number, quality number and graders name in the note
book
Remarks:
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
________________________________________________________________________________________
National Productivity Council, Bangalore.
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 25
Designation Proposed Manpower - - - 18
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
2
3
4
5
6
7
8
9
10 1 1 270.00 270.00
11 1 200 0.31 62.00
A 6955.33
B 17
C 8137.74
D 480
E 67.81%
F 18
G 94.19%
90.00
2. The present practice of each person grading 1000 meters each has been aggregated for the 25
graders as 25000 meters per shift
Remarks:
1. Point 1-7, the frequency is mentioned in meters
Unload the folded fabric near to the work table
Basic Workload per Shift ( in man minutes)
WLS No: CMF/18
WORK LOAD DETAILS SHEET
Checking, Mending &
finishing
Shifts A B C G
Finish Folding
Grading
THAN Grader
Activity Description
1 Cleaning the grading table before starting the grading.
Put folded piece on the table for grading.
Check the piece throughly .
Take out the fresh THAN , Safari ,Suit length , PL
,Cut and FRC to avoid the defects.
Recording the THAN, PL,and FRC in the grading
inspection sheet.
Send back the fabric for rectification which is having
stain, crease, seinging line.Wrapper mark, width
variation to process house
0.26 6533.33
Proposed Utilisation(%)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Discuss with Incharge, get clarifications etc,.
90.00
Put the damage fabric on the damage table for showing
the defects the concerned departmental Head.
Put the PL/Cut Length / and FRC in the specified area.
Put the stamp of category wise on PL/CL/ and FRC.
25000
1 1
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 9
Designation Proposed Manpower - - - 7
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
2
3
4
5
6
7
8 1 1 175 175
9 1 58 0.31 17.98
A 2743.48
B 17
C 3209.87
D 480
E 74.30%
F 7
G 95.53%
2515.5
35
Unload the folded fabric near to the work table
Basic Workload per Shift ( in man minutes)
Discuss with Incharge, get clarifications etc,.
1 5850 0.43
1 1
1. Point 1-5, the frequency is mentioned in meters
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
35
Put the stamp of category wise on PL/CL/ and FRC.
Put the PL/Cut Length / and FRC in the specified area.
Remarks:
G
Finish Folding
2. The present practice of each person grading 650 meters each has been aggregated for the 9 graders
as 5850 meters per shift
Cleaning the grading table before starting the grading.
Put folded fabric piece on the table for grading.
Check the piece throughly .
Take out the fresh , Safari ,Suit length , PL ,Cut and
FRC to avoid the defects.
Recording the PL,and FRC in the grading inspection
sheet.
Proposed Manpower per shift
Proposed Utilisation(%)
Grading
Cut piece Grader
Activity Description
WLS No: CMF/19
WORK LOAD DETAILS SHEET
Checking, Mending &
finishing
Shifts A B C
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 2
Designation Proposed Manpower - - - 2
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 2 19 8.10 307.80
2 2 19 4.14 157.32
A 465.12
B 14
C 530.24
D 480
E 55.23%
F 2
G 55.23%
Remarks:
1. As per data provided, 15000 meters ie., 1500 thans have to be transported daily. Out of this 50
% has been considered as transporting upto the work table and which involves no unloading and 50
% has been considerd as transporting to the concerned area and unloading in that area. Also in each
trip on an average 40 thans are transported, hence there is a need to make 38 trips per shift. 19 trips
are for option 1 and 19 trips are for option 2.
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Lift THAN from the grading sheet and shift to the
patti for folding and unload in the concerned area
Basic Workload per Shift ( in man minutes)
Grading
Loader
Activity Description
Lift THAN from the grading sheet and shift to the
patti for folding
WLS No: CMF/20
WORK LOAD DETAILS SHEET
Checking, Mending
& finishing
Shifts A B C G
Finish Folding
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 3
Designation Proposed Manpower - - - -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 15000 0.03 480.00
A 480.00
B 17
C 561.60
D 480
E 39.00%
F 2
G 58.50%
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
3. Keeping in mind the random nature of occurrence of these events, a manpower of two personnel
is recommended and the utilization level is 58.5 % each per shift.
Proposed Utilisation(%)
Remarks:
1. As per data provided, 10 % of the thans require to be kitty mended every day. Daily 1500 thans
are produced, hence 150 thans may require kitty mending.
2. In the 216 meters graded, kitty mending was performed 5 times and time spent was 6.95
minutes. Extrapolating this to 15000 meters we obtain the time thans may require kitty mending in
a shift.
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Grading
Kitty Mender
Activity Description
Based on the calls of the individual graders, go to the
concerned table and rectify the defects.
WLS No: CMF/21
WORK LOAD DETAILS SHEET
Checking, Mending
& finishing
Shifts A B C G
Finish Folding
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 1
Designation Proposed Manpower - - - 1
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 550 0.30 165.00
2 1 550 0.27 147.40
A 312.40
B 14
C 356.14
D 480
E 74.20%
F 1
G 74.20%
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Remarks:
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Grading
Bar code Sticker
Operator
Activity Description
Pick thans from the trolley, input meters into SAP,
take printout of the bar code sticker and place in the
than bundle. Write details in the register.
Affix one sticker onto the fabric, the other onto the
tag, attach tag using tag gun, forward to than folder
Basic Workload per Shift ( in man minutes)
WLS No: CMF/22
WORK LOAD DETAILS SHEET
Checking, Mending &
finishing
Shifts A B C G
Finish Folding
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 1
Designation Proposed Manpower - - - 1
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 990 0.27 267.30
2 1 30.00 30.00
3 1 10.00 10.00
4
A 297.30
B 14
C 338.92
D 480
E 70.61%
F 1
G 70.61%
Remarks:
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Grading
Helper
Activity Description
Check alignment and cut end of piece
Provide raw material for packing
Basic Workload per Shift ( in man minutes)
Bring water bucket for washing the stamps
Assist in joining the wrappers in case of graviera
packing
Finish Folding
WLS No: CMF/23
WORK LOAD DETAILS SHEET
Checking, Mending &
finishing
Shifts A B C G
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 1
Designation Proposed Manpower - - - 1
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
2
A 366.85
B 15
C 421.88
D 480
E 87.89%
F 1
G 87.89%
Proposed Manpower per shift
Proposed Utilisation(%)
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Remarks:
1. 275 thans per day has been considered based on the data provided. Based on the field study
conducted, the time provided is for a than with an average length of 11.6 meters.
1 275 1.334 366.85
Net Available man-mins
Present Utilisation(%)
B C
Grading
THAN Folder
Activity Description
Check the than length, wrap the fabric on the stra board
patti, transfer the than to the screening work station
G
Finish Folding
Total Workload ( in man minutes )
Show the defective piece to the officer, and return back
to the grader for rectification of the same
WLS No: CMF/24
WORK LOAD DETAILS SHEET
Checking, Mending &
finishing
Shifts A
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 1
Designation Proposed Manpower - - - 1
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 550 0.62 341
A 341.00
B 15
C 392.15
D 480
E 81.70%
F 1
G 81.70% Proposed Utilisation(%)
Remarks:
1. 550 thans per day has been considered based on the data provided.
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Grading
Screener
Activity Description
Transfer the print screening on the than and forward
the than to stamping
WLS No: CMF/25
WORK LOAD DETAILS SHEET
Checking, Mending
& finishing
Shifts A B C G
Finish Folding
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 1
Designation Proposed Manpower - - - 1
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 550 0.46 253
A 253.00
B 15
C 290.95
D 480
E 60.61%
F 1
G 60.61%
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Remarks:
1. 550 thans per day has been considered based on the data provided.
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Grading
Stamper
Activity Description
Stamp the quality number, shade number, meters and
forward the than to the next work station
Basic Workload per Shift ( in man minutes)
WLS No: CMF/26
WORK LOAD DETAILS SHEET
Checking, Mending
& finishing
Shifts A B C G
Finish Folding
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 1
Designation Proposed Manpower - - - 1
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 550 0.47 258.5
A 258.50
B 14
C 294.69
D 480
E 61.39%
F 1
G 61.39%
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Remarks:
1. 550 thans per day has been considered based on the data provided.
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Grading
Wrapper Man
Activity Description
Stamp the quality number, shade number, meters and
forward the than to the next work station
Basic Workload per Shift ( in man minutes)
WLS No: CMF/27
WORK LOAD DETAILS SHEET
Checking, Mending
& finishing
Shifts A B C G
Finish Folding
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 1
Designation Proposed Manpower - - - 1
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 550 0.462 254.1
A 254.10
B 14
C 289.67
D 480
E 60.35%
F 1
G 60.35%
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Remarks:
1. 550 thans per day has been considered based on the data provided.
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Grading
Poly Bag Man
Activity Description
Put the than in the specified poly bag, close mouth with
cello tape and place in patti
Basic Workload per Shift ( in man minutes)
WLS No: CMF/28
WORK LOAD DETAILS SHEET
Checking, Mending &
finishing
Shifts A B C G
Finish Folding
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 1
Designation Proposed Manpower - - - 1
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 1100 0.29 319
A 319.00
B 14
C 363.66
D 480
E 75.76%
F 1
G 75.76%
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Remarks:
1. 550 thans per day has been considered based on the data provided. One person mans two lines
presently. As the utilization per line is 76 %, the present manning pattern may be continued
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Grading
Than Segregator
Activity Description
Put the than in the specified poly bag, close mouth
with cello tape and place in patti
Basic Workload per Shift ( in man minutes)
WLS No: CMF/29
WORK LOAD DETAILS SHEET
Checking, Mending &
finishing
Shifts A B C G
Finish Folding
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 12
Designation Proposed Manpower - - - 12
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 600 0.25 151.07
2 1 600 0.07 41.4
3 1 1 3.95 3.945
3.1
3.1
4 1 600 0.14 86.3
A 282.72
B 14
C 322.30
D 480
E 67.14%
F 1
G 67.14%
Remarks:
1. 600 pieces per day has been considered based on the data provided.
Arrange for packing
Take trolley, go to the storage, get pattis, unload and
arrange in work place
Get poly baks from storage
Pack the PL using the pattis, poly covers
Net Available man-mins
Present Utilisation(%)
PL packing
Bar code operator cum
packer
Activity Description
Count, generate bar code for the PL, affix two numbers
on each, arrange bundle and keep in the prescribed place
Proposed Manpower per shift
Proposed Utilisation(%)
Sign on sticker
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
WLS No: CMF/30
WORK LOAD DETAILS SHEET
Checking, Mending &
finishing
Shifts A B C G
Finish Folding
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 4
Designation Proposed Manpower - - - 4
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 2400 0.14 336.8
A 336.80
B 14
C 383.95
D 480
E 79.99%
F 1
G 79.99%
Remarks:
1. 2400 pieces per day has been considered based on the data provided.
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Basic Workload per Shift ( in man minutes)
PL packing
Screener
Activity Description
Transfer the print screening on the PL
WLS No: CMF/31
WORK LOAD DETAILS SHEET
Checking, Mending &
finishing
Shifts A B C G
Finish Folding
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 2
Designation Proposed Manpower - - - 1
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 2 400 0.13 104
A 104.00
B 14
C 118.56
D 480
E 12.35%
F 1
G 24.70%
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Remarks:
1. 10000 kg to be segregated per month which works out to be 400 kg per day.
2. One person recommended for this activity.
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
PL packing
FRC Sorter
Activity Description
Segregate the fabric grade-wise, unit wise, pack in the
bag and keep aside
Basic Workload per Shift ( in man minutes)
WLS No: CMF/32
WORK LOAD DETAILS SHEET
Checking, Mending &
finishing
Shifts A B C G
Finish Folding
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 8 8 8 -
Designation Proposed Manpower 7 7 7
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 1 35.00 35
2 1 80 2.55 204
3 1 8000 0.25 1990.4
4 1 2 4.64 9.28
5 1 1 105.00 105.00
A 2343.68
B 17
C 2742.11
D 440
E 77.90%
F 7
G 89.03% Proposed Utilisation(%)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Discussion with superiors
Remarks:
1. For an inspection of 8000 meters per day, 7 machines need to be operated per day.
Basic Workload per Shift ( in man minutes)
Carry out inspection, put flag where defect is sighted,
enter details in the inspection register
Transport empty horse to the process house, check
materials on new horse, and transport the new horse to
the rolling inspection machine
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Rolling cum inspection
Inspector
Activity Description
Clean machine before starting inspection
Change output rolls - Remove the completed roll and
place on adjacent rollers, insert cardboard roll & roll
some fabric onto it, cut piece and throw in dust bin, cut
one sample piece and keep aside, tag the completed roll,
write details on the completed r
WLS No: CMF/33
WORK LOAD DETAILS SHEET
Checking, Mending &
finishing
Shifts A B C G
Finish Folding
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 6 6 4 -
Designation Proposed Manpower 4 4 4
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 2 133 1.31 348.46
2 2 133 0.36 95.228
3 1 133 0.25 33.25
4 2 133 0.66 175.028
5 1 33.25 1.18 39.24
6 1 133 0.36 47.88
A 739.08
B 14
C 842.55
D 450
E 31.21%
F 4
G 46.81%
B
Total Workload ( in man minutes )
Packers
Wrap rolls with poly cover, put cello tape
Stack roll in the designated place and back
WLS No: CMF/34
WORK LOAD DETAILS SHEET
Checking, Mending &
finishing
Shifts A
Write the details of rolls being packed in a register
Proposed Manpower per shift
B & R Inspection
Remarks:
Activity Description
b) One person for writing the details in the register and generating bar code
C G
Finish Folding
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Proposed Utilisation(%)
Pick rolls from the trolley, place on table, put poly covers,
cut extra threads, attach two stickers ('face side' and 'fabric
once cut cannot be claimed') and push rolls to the next
work station
Net Available man-mins
Generate bar code, affix stickers on the rolls
c) One person for stacking the rolls and acting as an online reliever for the two personnel mentioned in
a)
1. For processing of 8000 meters per day, 133 rolls need to be processed @ 60 meters per roll.
Transport rolls from the rolling inspection to work place
2. Instead of the six personnel per shift a manning of four is recommended:
a) Two personnel for performance of activities 1,2 and 4
Present Utilisation(%)
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 4
Designation Proposed Manpower - - - 4
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 2 160 1.68 538.24
2 1 480 0.68 327.36
A 865.60
B 14
C 986.78
D 480
E 51.40%
F 4
G 51.40%
WLS No: CMF/35
WORK LOAD DETAILS SHEET
Checking, Mending &
finishing
Shifts A B C G
Finish Folding
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Segregate shade wise and stack
B & R Inspection
Bale Helpers
Activity Description
Open bales of outsourced fabric, cut sample piece
Remarks:
1. Presently 40 bales per person per day are processed ie., for 4 personnel it amounts to 160 bales per
day.
2. In each bale there are three sets of fabric, hence for activity 2, 480 numbers of sets have been
considered.
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 1
Designation Proposed Manpower - - - 1
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
1.1 1 67 0.11 8.23
1.2
1.3
2
2.1 1 20 2.86 57.2
2.2 1 20 1.74 34.78
2.3 1 1 2.00 2.00
A 132.36
B 15
C 152.22
D 480
E 31.71%
F 1
G 31.71%
WLS No: CMF/36
WORK LOAD DETAILS SHEET
Checking, Mending &
finishing Shifts A B C G
Finish Folding
As per the list provided by the marketing department,
arrange roll cutting as per serial number, and handover to
the sample department.
Affix stickers
Basic Workload per Shift ( in man minutes)
30.15
B & R Inspection
Sample Man
Activity Description
Sample Preparation
Rest & Relaxation Allowances ( % )
Pack it in polythene cover and handover to marketing
department peon
Grading
Inspect fabric, cut sample pieces as per requirement,
affix marks, put in poly cover and pack.
Prepare challan
1 67 0.45
Handover the hanger material in the sample room
Proposed Utilisation(%)
Remarks:
1. Activity 1 - 200 samples per three days considered
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 1
Designation Proposed Manpower - - - 1
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 550 0.33 181.50
A 181.50
B 14
C 206.91
D 480
E 43.11%
F 1
G 43.11%
WLS No: CMF/37
WORK LOAD DETAILS SHEET
Checking, Mending &
finishing Shifts A B
Remarks:
1. The walk time is distributed to three thans.
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Total Workload ( in man minutes )
Proposed Utilisation(%)
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
C G
Finish Folding
Input meters into SAP, take printout of the bar code
sticker and affix.
B & R Inspection
Bar code Sticker
Operator
Activity Description
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 1
Designation Proposed Manpower - - - 1
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 1 120.00 100.00
2 1 1 30.00 30.00
3 1 1 20.00 20.00
4 1 1 20.00 20.00
5 1 1 20.00 20.00
6 1 1 30.00 30.00
7 1 1 20.00 20.00
8 1 1 15.00 15.00
A 255.00
B 14
C 290.70
D 480
E 60.56%
F 1
G 60.56%
B & R Inspection
Computer operator
Activity Description
Receive '4-point' inspection report from finish folding
inspection, compute fresh and damage, input details in
excel and in SAP
WLS No: CMF/38
WORK LOAD DETAILS SHEET
Checking, Mending &
finishing Shifts A B C G
Finish Folding
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Input details of the loom wise defects into the excel sheet
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Remarks:
Input in excel the details of the roll number, date, meters,
points, grader, beam number
Calculate the fresh point / 100 square meter and total
points / 100 square meters and input into excel sheet
Find out the spinning lot number from SAP and input into
spinning value loss report
Prepare daily quality wise report
Prepare main damage report for damages
Maintain excel sheet detailing the meters of fabric given
to process house and received from process house
Net Available man-mins
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 2
Designation Proposed Manpower - - - 1
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 3 44.00 132.00
2 1 3 44.00 132.00
3 1 1 3.00 3.00
A 267.00
B 13
C 301.71
D 450
E 33.52%
F 1
G 67.05%
WLS No: CMF/39
WORK LOAD DETAILS SHEET
Checking, Mending &
finishing
Shifts A B C G
Finish Folding
Clean with mop the finish folding, B & R inspection and
grading area
Collect dust and waste in the polythene covers and
tranfer to the waste yard
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Finish Folding
Cleaner
Activity Description
Clean with broom stick the finish folding, B & R
inspection and grading area
Proposed Utilisation(%)
Remarks:
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 1
Designation Proposed Manpower - - - 1
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 1 30.00 30.00
2 1 1 10.00 10.00
3 1 80 1.00 80.00
4 1 1 30.00 30.00
5 1 1 30.00 30.00
6 1 1 40.00 40.00
7 1 1 30.00 30.00
8 1 1 10.00 10.00
A 260.00
B 15
C 299.00
D 480
E 62.29%
F 1
G 62.29%
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Remarks:
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Ensure proper tagging, stickering and in case the
personnel face any problems, resolve the same
Attend inter-departmental meeting daily at 3.30 pm
Periodically check whether the production targets are
being achieved by the graders
Show the damaged pieces to the superior and explain the
defects
Provide stationery to the personnel as per requirements
Finish Folding
Monitor
Activity Description
Check the position of materials in process house, compare
with the mail already received from PPC, and decide on
the number of personnel to deploy for THAN and cut
piece
In the direct fold machine check the length and in case of
any problem, get it rectified by the fitter
Give instructions to the graders and ensure that the
production is completed as per schedule and on time
WLS No: CMF/40
WORK LOAD DETAILS SHEET
Checking, Mending &
finishing
Shifts A B C G
Finish Folding
________________________________________________________________________________________
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________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower - - - 1
Designation Proposed Manpower - - - 1
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 1 30.00 30.00
2 1 1 45.00 45.00
3
a)
b) 1 1 30.00 30.00
c) 1 1 90.00 90.00
4 1 1 30.00 30.00
5 1 1 15.00 15.00
A 240.00
B 15
C 276.00
D 480
E 57.50%
F 1
G 57.50%
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Remarks:
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
10 meter sample has been cut from each quality
Party's requirement of rolls is intimated to all the
individual workmen
20 cm is cut from each roll which is completed
Scrutinize the fabric roll shade and csv report received
In case of customer complaints, collect information,
investigate and inform superiors
B & R Inspection
Finish Checker
Activity Description
Receive hand written list from the process house
regarding the materials which will be handed over by
the process house along with the approval slips of QC,
schedule the material on the machines
Check finish of fabrics in process house by feel, note in
register, write details on card, and place card in the
horse
Ensure that
WLS No: CMF/41
WORK LOAD DETAILS SHEET
Checking, Mending
& finishing Shifts A B C G
Finish Folding
________________________________________________________________________________________
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________________________________________________________________________________________
Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
11. PROCESS HOUSE - PRODUCTION
________________________________________________________________________________________
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___________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
11.0
11.1
I II III G T I II III G T
1 Grey Seggreation 2 2 3 - 7 2 2 2 - 6
2
Sample Card
Preparation
- - - 1 1 - - - 1 1
3 Grey Plaiting 1 1 - - 2 1 1 - - 2
4 Grey Batching 3 3 3 - 9 2 2 2 - 6
5
Job fabric computer
data entry
- - - 1 1 - - - 1 1
6 Grey incharge - - - 1 1 - - - 1 1
7 Grey Rolling 4 4 - - 8 3 3 - - 6
8
Batch Card and Report
preparation
2 1 - - 3 2 2 - - 4
9 Relax scouring Range 8 8 8 - 24 6 6 6 - 18
10 Weight reduction 6 6 6 - 18 4 4 4 - 12
11 Dolly Winch 2 2 - - 4 2 2 - - 4
12 Jumbo Jigger 2 2 2 - 6 2 2 2 - 6
13 Hydro Extraction 1 1 1 - 3 2 2 2 - 6
14 Jet Dyeing 8 8 8 - 24 6 6 6 - 18
15 Auto Jigger 3 3 3 - 9 3 3 3 - 9
16 Stores -1 1 1 1 - 3 1 1 1 - 3
17 Singeing 3 3 - - 6 3 3 - - 6
18 Stenter 12 12 12 - 36 12 12 12 - 36
19 Kier decatising 2 2 2 - 6 2 2 2 - 6
20 MD 2 2 2 - 6 2 2 2 - 6
21 Super Finish 2 2 2 - 6 2 2 2 - 6
22 Shrinking Range 2 2 2 - 6 2 2 2 - 6
PROCESS HOUSE - PRODUCTION
Proposed Manpower
Remarks S. No Section / Work area Designation
SPH
Present Manpower
Manpower Deployment
_________________________________________________________________________________________________________________________________
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___________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
11.0
11.1
I II III G T I II III G T
PROCESS HOUSE - PRODUCTION
Proposed Manpower
Remarks S. No Section / Work area Designation
SPH
Present Manpower
Manpower Deployment
23 Calendar 2 2 2 - 6 2 2 2 - 6
24 Checker 1 1 - - 2 1 1 - - 2
25 Press 1 1 - - 2 1 1 - - 2
26 Sample Process 1 1 - - 2 1 1 - - 2
27 Gun spotting 1 1 - - 2 1 1 - - 2
28 Jobber 1 - - - 1 1 - - - 1
29 Sweeper 1 - - 4 5 1 - - 3 4
30 Trolley movement 1 1 1 - 3 1 1 1 - 3
31 Stitching 1 1 - - 2 1 1 - - 2
32 Computer operator - - - 1 1 - - - 1 1
33 Hand spotting - - - 2 2 - - - 2 2
34 Machine cleaning 1 1 - - 2 1 1 - - 2
35 Stores -2 - - - 1 1 - - - 1 1
Total 77 74 58 11 220 70 68 51 10 199
SPH
The average engagement of manpower in this department has been 175 (without considering over time).
_________________________________________________________________________________________________________________________________
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________________________________________________________________________________________
Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
11.0
11.2
11.2.1
a)
b)
c)
d)
e)
f)
g)
h)
Batch card and report preparation - deploy 2 personnel in shifts A and
B instead of the present deployment of 2 in A shift and 1 in B shift
based on workload
Relax scouring - deploy 6 personnel for two machines instead of the
present deployment of 8 personnel for two machines
Hydro extraction - deploy 2 personnel per shift instead of the present
deployment of 1 per shift based on workload
Jet Dyeing - deploy 6 personnel - one operator for each machine and
two helpers for 4 machines, instead of the present deployment of 8
personnel for 4 machines
Sweepers - deploy 4 sweepers per day instead of the present
deployment of 5 per day
Proposed Changes & Observations
PROCESS HOUSE - PRODUCTION
Proposed Changes
Grey Batching - deploy 2 personnel per shift instead of the present
deployment of 3 per shift based on worklaod
Grey Rolling - deploy 3 personnel per shift instead of the present
deployment of 4 per shift based on worklaod and the work pattern
Weight reduction - deploy 4 personnel for three machines instead of
the present deployment of 6 personnel. One operator is assigned for
each machine and one common helper for all three machines
________________________________________________________________________________________
National Productivity Council, Bangalore.
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Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
11.0
11.3
S.No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
Machine cleaning PHP/35
Stores - 2 PHP/36
Stitching PHP/32
Computer operator PHP/33
Hand spotting PHP/34
Jobber PHP/29
Sweeper PHP/30
Trolley movement PHP/31
Press PHP/26
Sample processing PHP/27
Gun spotting PHP/28
Shrinking range PHP/23
Calendar PHP/24
Checker PHP/25
KD Lycra PHP/20
Multi Decatising PHP/21
Super finish PHP/22
Singeing PHP/17
Stenter PHP/18
KD Domestic PHP/19
Jet Dyeing PHP/14
Auto jigger PHP/15
Stores - 1 PHP/16
Dolly winch PHP/11
Jumbo jigger PHP/12
Hydro extractor PHP/13
Batch Card and Report preparation PHP/08
Relax Scouring PHP/09
Weight reduction machine PHP/10
Job fabric computer entry PHP/05
Grey Incharge PHP/06
Grey rolling PHP/07
Sample card preparation PHP/02
Grey Plaiting PHP/03
Grey batching PHP/04
PROCESS HOUSE - PRODUCTION
Workload Sheets Summary
Area of work WLS Number
Grey segregation PHP/01
________________________________________________________________________________________
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Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Grey Seggregation
Work Centre Present Manpower 2 2 3 -
Designation Proposed Manpower 2 2 2 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
1 1 10.21 10.21
2
2 200 1.60 640.00
3
2 17 2.34 79.63
4
2 17 1.41 48.08
A 777.91
B 13
C 879.04
D 900
E 97.67%
F 2
G 97.67%
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Remarks:25000 mtrs to be transferred to the batching m/c per shift(average 120 mtrs in each
roll.Therefore 200 rolls taken as the frequency
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Shift rolls to batching m/c area
Take out the required rolls to be transferred to the
batching m/c and place them vertically
Carry and load rolls on to the trolley (12 rolls on 1
trolley)
Unload all the rolls on the ground near batching m/c
Seggregation
Gey Seggreation
Activity Description
Take the programe from grey incharge
WLS No: PHP/01
WORK LOAD DETAILS SHEET
G Shifts A B C
PHP
________________________________________________________________________________________
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Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Grey Seggreation
Work Centre Present Manpower - - - 1
Designation Proposed Manpower - - - 1
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
1 1 10.11 10.11
2
1 7 6.77 47.39
3
1 7 30.03 210.21
4
1 7 0.77 5.41
5
1 1 30.14 30.14
A 303.26
B 13
C 342.68
D 480
E 71.39%
F 1
G 71.39%
WLS No: PHP/02
WORK LOAD DETAILS SHEET
G Shifts A B
Mark the attendance of all the workers in grey
seggrigation
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
PHP
Sample Card Preparation
Sample Card Preparator
Activity Description
Proposed Utilisation(%)
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
C
Remarks:
take the strips of all the batches of domestic made by the
grey batching operator
Cut the samples and staple the same on sample cards and
prepare three sets of cards
Put the quality no batch no and shade no against each
cutting
Deliver one set of cards to folding dept.,one set to process
house and the third set to marking
________________________________________________________________________________________
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Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Grey Seggregation
Work Centre Present Manpower 1 1 - -
Designation Proposed Manpower 1 1 - -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
1 1 5.44 5.44
2
1 3 8.44 25.32
3
1 46 0.92 42.24
4
1 3 49.20
5
1 3 1.42 4.26
6
1 3 1.74 5.23
7
1 3 10.72 32.17
8
1 3 6.54 19.62
9
1 3 3.45 10.35
A 144.63
B 13
C 163.43
D 450
E 36.32%
F 1
G 36.32%
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Remarks: Production per machine per shift has been taken as 5500 mtrs.Average 120 mtrs in each
roll.One trolley contains 2000 mtrs of fabric after being plaited
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Basic Workload per Shift ( in man minutes)
Carry the trolley to place near batch m/c
Load 1 roll for plaiting (tie with old running cloth)
Opening rolls kept near the machine by grey
seggrigator on plaiting machine in the trollies or
table(2000 mtr on one table) (machine element)
Locate the empty trolly or table in proces house and
take it to the plaiting machine
Adjust the plaits on the table
Plaiting
-
Activity Description
Prepare and stitch all the pieces together(in 2000
mtr,16 stitches for 17 pieces are to be made)
Take the batch card from batchcard printer and tie
the same with the end piece of the trolly
Carry the trolly in the process house according to the
instruction written on the Batch processing card or
according to the process house shift supervisor'
instruction
Get the programe for the machine from the shift
Supervisor
WLS No: PHP/03
WORK LOAD DETAILS SHEET
G Shifts A B C
PHP
________________________________________________________________________________________
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________________________________________________________________________________________
Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Grey Seggreation
Work Centre Present Manpower 3 3 3 -
Designation Proposed Manpower 2 2 2 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1 1 1 4.55 4.55
2
1 1 15.11 15.11
3
1 46 5.56 255.76
4
1 138 0.26 36.39
5
1 138 0.25 34.22
6
1 7 98.00
7
1 138 0.66 91.38
8
1 7 1.54 10.77
9
1 7 2.24 15.68
A 463.86
B 13
C 524.16
D 1350
E 38.83%
F 2
G 58.24%
WLS No: PHP/04
WORK LOAD DETAILS SHEET
G Shifts A B C
PHP
Locate the empty rolls in proces house and take it to
the Batching machine and aligned the same with
machine batching device
Load roll on one of the two loading points
Grey Batching
-
Activity Description
Get the programe for the machine from the shift
Total Workload ( in man minutes )
Remarks:1. Production per machine per shift has been taken as 16500 mtrs.Average 120 mtrs in
each roll
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Opening time of 1 batch of 2500 mtr (average length)
in fabric accumulator with the help of machine
(machine element)
Writing no on rolls at the time of rolls being delivered
by grey segregation persons (3 rolls at a time) and
note down all the pc details on a format and give it to
batch card printer ,take the batch card from batchcard
printer and tie the same with the end piece of the
trolly
Giving 1 roll at a time to the grey batching handling
person
Rest & Relaxation Allowances ( % )
After opening of one roll,write batch no on new roll
and stitch with previous roll
Remove the completed roll
Deliver the roll in the process house according to the
instruction written on the Batch processing card or
according to the process house shift supervisor'
instruction
Basic Workload per Shift ( in man minutes)
________________________________________________________________________________________
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________________________________________________________________________________________
Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Gey Seggreation
Work Centre Present Manpower - - - 1
Designation Proposed Manpower - - - 1
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
1 1 6.67 6.67
2
1 1 65.56 65.56
3
1 1 90.66 90.66
4
1 1 45.34 45.34
5
1 1 37.65 37.65
6
1 1 34.65 34.65
A 280.53
B 13
C 317.00
D 480
E 66.04%
F 1
G 66.04%
WLS No: PHP/05
WORK LOAD DETAILS SHEET
G Shifts A B C
PHP
After varification of goods received from job weaving
against challan the job fabric entry operator takes all the
challans from grey incharge
Prepare the challan of all the pcs and give it to the logistic
dept. for the dispatch of the same
After entering all the pcs whether received from Job
weaving or sent for job processing he hand over all the
challans to grey incharge for filing
Job fabric computer data entry
Operator
Activity Description
Find out all the PO and line item and write it down on the
challan against which the goods has received from the
system
Receive all the pcs in the system and book the yarn
consumption against the line item recieved and if the yarn
stock is not in the system then he contact to the job weaving
person and get it changed in the PO
In case of goods to be sent to job processing he is entering
all the pcs and transfer it to job vendor location in the
system
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Remarks:
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
________________________________________________________________________________________
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________________________________________________________________________________________
Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Gey Seggreation
Work Centre Present Manpower - - - 1
Designation Proposed Manpower - - - 1
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
1 1 15.78 15.78
2
1 1 20.45 20.45
3
1 25 5.65 141.25
4
1 3 15.56 46.68
5
1 1 30.00 30.00
6
1 1 36.87 36.87
A 291.03
B 13
C 328.86
D 480
E 68.51%
F 1
G 68.51%
WLS No: PHP/06
WORK LOAD DETAILS SHEET
G Shifts A B C
PHP
Take the daily grey issue programme from PPC dept.
Maintain the record of the goods coming from job
weaving and sent for job processing
Grey incharge
Grey incharge
Activity Description
Show this prog. to process head and take the approval
from him for issuing the same
In case of B&R goods prepare the shade continuity card
and show the same along with previous supply to
process head for getting the clearance for grey issue
According to the stock reoprt and the grey issuance prog
give instruction to grey seggregator, plaiter, grey batcher
Co-ordinates with PPC, process head and Mending dept.
for different issues related to grey seggregation
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Remarks:
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
________________________________________________________________________________________
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Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section Grey Seggregation
Work Centre Present Manpower 4 4 - -
Designation Proposed Manpower 3 3 - -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
1 1 10.55 10.55
2
1 46 0.94083 43.28
3
1 46 2.60
4
1 46 0.21 9.73
5
2 46 0.08 6.93
6 1 46 0.28 12.90
7
1 46 0.22 9.95
8
1 46 0.26 12.01
9
2 46 0.09 8.60
10
1 46 0.25 11.40
11 1 45 0.14 6.33
12
2 35 2.45 171.50
13
2 35 0.08 5.33
14 1 35 0.23 8.15
15 1 34 0.19 6.30
16 1 35 0.29 9.98
A 332.95
B 13
C 376.24
D 1800
E 20.90%
F 3
G 27.87%
Tally against the challan the incoming material
Carry the rolls to stack
Return for next roll
If the Mending goods come from outside they tally it
against the challan and put them in the trollies.
Place on trolley after rolling
Return for next roll
Return for next roll
Note in register the details of the rolls transferred to the
stack
Shifting the rolls to Grey Plaiting
Destack and load the rolls on shoulder
Carry the rolls to the plaiting m/c
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Remarks:1. Production per machine per shift has been taken as 5500 mtrs.Average 120 mtrs in each
roll.Average 5 lakh metres comes from outside per month.Therefore 70 rolls comes in two shifts
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
From Job weaving(outside) to stacking in grey
Destack and load the rolls on to the shoulder
Rolling
-
Activity Description
Carry the rolls to stack
Shifting the rolls to Stack from rolling (Loom wise)
Destack and load the rolls on to the shoulder
Take all the pcs from mending(after final checking) and
job weaving in lump form and bring one trolley near the
m/c and adjust (tie with old fabric and note the details
in the register)
Make individual rolls of all the pcs on rolling
machine(120-130 mtr average) (machine element)
2. Three personnel are recommended with a utilization of 28 % because of the simultaneous
occurance of activities
WLS No: PHP/07
WORK LOAD DETAILS SHEET
G Shifts A B C
PHP
Preparatory Activities
Bring iron rods for rolling purpose
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Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Gey Seggreation
Work Centre Present Manpower 2 1 - -
Designation Proposed Manpower 2 2 - -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
1 1 12.78 12.78
2
1 1 98.87 98.87
3
1 1 87.78 87.78
4
1 1 25.88 25.88
5
1 1 4.77 4.77
6
1 1 66.78 66.78
7
1 20 15.54 310.8
8
1 20 1.43 28.6
A 636.26
B 13
C 718.97
D 900
E 79.89%
F 2
G 79.89%
Book the consumption of all the pcs production order wise
in the system and take out the batch processing card
Hand over the batch processing card to grey batcher or the
paiter for attatching the same with the material
Prepare the summary of grey activities and hand it over to
PPC dept. and process house MIS dept.
Batch Card and Report
preparation
Batch Card and Report preparator
Activity Description
Take the pc wise detail of each batch from grey plaiter and
grey batcher
Total Workload ( in man minutes )
WLS No: PHP/08
WORK LOAD DETAILS SHEET
G Shifts A B C
PHP
Make the production order of process house
Remarks:
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Take the report of grey reciept from mending and the job
weaving on the previous day
Prepare the grey issue report of previous day(tallying
outside and inside cloth and note category wise production)
Prepare the stock report of grey dept.((Job mending
out+previous day stock)-export delivery of previous day))
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
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Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Work Centre Present Manpower 8 8 8 -
Machine Name Proposed Manpower 6 6 6 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
4 1/3 109.8 146.4
2
1 1 5.43 5.4
3 1 1 7.21 7.2
4
2 6 7.84 94.0
5
1 1 433.33
6
1 2 7.91 15.8
7
1 4 1.87 7.5
8
1 3 43.66 131.0
9
2 6 5.43 65.2
10
1 3 30.00 90.0
A 562.52
B 1125.04
C 13
D 1271.30
E 3600
F 35.31%
G 6
H 47.09%
locate the goods to be run on the machine
stitch the end of the material with previous material and
ensure all cloth ends are tied together.Rectify the same if
found to be broken and start the machine
set the machine parameter on the screen and ensure its
occurance(average speed of the m/c =30 mtr/min)
(machine element)
get the chemical issue slip from the shift supervisor and
give the issue slip to chemical substore and get the
chemical from there for the machine
Rest & Relaxation Allowances ( % )
Basic Workload per Shift ( in man minutes) of two relax scouring machines
Basic Workload per Shift ( in man minutes)
Remarks: 1. Production per machine per shift has been taken as 13000 mtrs.Average 2500 mtrs in
each trolley and average speed of the m/c =30 mtr/min).
Dissolve the chemical in the bucket and dose the same in
the machine
Cleaning of all the chambers of scouring as well as
drying zone with air and water pressure
after reciving the goods at delivery end put the tag of
next process on the trolly and deliver it to the designated
place of next process and cover the trolly with HDPE
trolly cover
Relieve the three operators at loading,relaxing and drying
areas and manages the work of all the three operators
Proposed Utilisation(%)
Total Workload ( in man minutes )
Net Available man-mins
Present Utilisation(%)
C
PHP
Relax scouring Range
Relax scouring range
Activity Description
clean the filter of the washing cambers,clean the filter of
the dryer and cleaning of all the chambers of scouring as
well as drying zone and full cleaning of the m/c
get the programe for the machine from the shift
Supervisor
Scouring area
Proposed Manpower per shift
2. Six personnel are recommended for 2 machines
WLS No: PHP/09
WORK LOAD DETAILS SHEET
G Shifts A B
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Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Scouring area
Work Centre Present Manpower 6 6 6 -
Machine Name Proposed Manpower 4 4 4 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
1 1 5.61 5.6
2
2 1 3.12 6.2
3
2 1 4.56 9.1
4
2 4 6.17 49.4
5
2 4 5.30 42.4
6
1 1 1.67 1.7
7
1 1 9.50 9.5
8
1 1 101.00
9
1 1 14.00
10
1 1 51.00
11
1 1 14.00
12
1 1 30.00
13
1 1 14.00
14
1 1 60.00
15
1 1 14.00
Get the programe for the machine from the shift
Supervisor
Take the temperature of the water in the m/c to 90
degree celcius and dissolve the chemical (caustic
+solite) in the dosing tank and dose the same in the
machine, hold water at 90 degree celcius and allow the
temp to drop down from 90 degree celcius to 70
degree celcius (machine element)
give the issue slip to chemical substore and get the
chemicals from there for the machine(caustic,solide
plus,soda ash,oxolic acid,acitic acid and vita foam in
case foam is being formed)
Drain water and load new water (machine element)
Load the fabric rope wise in the machine
Cleaning the windows of the m/c
Locate the goods to be run on the machine no 2 (1200
mtrs processed i.e. 2 beams of 600-650 mtr ) and clean
remaining chemicals
Load the fabric(1200 mtr and 300 mtr in one window)
in windows and note in the register
Stitch (12 stitches for 1200 mtr) both the ends of the
fabric loaded in windows
Drain water and load new water (machine element)
WLS No: PHP/10
WORK LOAD DETAILS SHEET
G Shifts A
set the machine parameter or program number on the
screen and ensure its occurance of the same
Weight reduction
Weight reduction
Activity Description
B C
PHP
Drain water and load new water(2800 lts in this case)
(machine element)
Drain water and load new water (machine element)
Take the temperature of the water in the m/c to 90
degree celcius and do hot wash (machine element)
Take the temperature of the water in the m/c to 90
degree celcius and dissolve the chemical (acitic acid
+auxilic acid) in the dosing tank a,hold water at 90
degree celcius (machine element)
Take the temperature of the water in the m/c to 90
degree celcius and and dissolve soda ash in the dosing
tank hold water at 90 degree celcius (machine
element)
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Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Scouring area
Work Centre Present Manpower 6 6 6 -
Machine Name Proposed Manpower 4 4 4 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
WLS No: PHP/10
WORK LOAD DETAILS SHEET
G Shifts A
Weight reduction
Weight reduction
Activity Description
B C
PHP
16
1 1 30.00
17
1 1 14.00
18
1 1 30.00
19
1 1 14.00
20
1 1 20.00
21
2 1 4.21 8.4
22
2 1 14.90 29.8
23
1 1 2.68 2.7
24 1 1 5.66 5.7
25
1 1 4.12 4.1
26
1 1 14.23 14.2
27
1 1 4.36 4.4
28
1 1 5.21 5.2
A 198.38
595.14
B 13
C 672.51
D 2700
E 24.91%
F 4
G 37.36%
Basic Workload per Shift ( in man minutes); 3 machines of the same kind
Present Utilisation(%)
Drain water and load new water (machine element)
Perform cool wash (machine element)
Drain water and load new water (machine element)
Take the temperature of the water in the m/c to 90
degree celcius and do hot wash (machine element)
Proposed Utilisation(%)
Proposed Manpower per shift
Bring on more trolley and place polythene sheets into
it
Unload the material in trolley
Tearing apart the stitched material
Take the trolley to reopenor
1 For each of the weight reduction machines one operator and one helper who will help all the
three operators and also act as an online reliever.
Tie the fabric with the old fabric already hung and run
the m/c till it passes to the other side of the reopenor
where it is coming after being reopened
Start reopening
after reciving the goods at delivery end put the tag of
dry for next process on the trolly and deliver it to the
designated place of drying process and cover the trolly
with polythene sheet
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
Remarks:
Basic Workload per Shift ( in man minutes)
Locate the empty trolly in the process house for next
fabric
Net Available man-mins
Unload the material in trolley
Wash at 90 degree celcius (machine element)
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Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Scouring area
Work Centre Present Manpower 2 2 - -
Machine Name Proposed Manpower 2 2 - -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
1 1 5.32 5.3
2
2 10 6.54 130.8
3
2 10 1.11 22.2
4
1 10 0.90 9.0
5
1 1 2.63 2.6
6
1 1 5.75 5.8
7
1 1 1.42 1.4
8
1 1 34.16
9
1 1 79.63
10
1 1 70.43
11 1 1 18.45
B C
PHP
Load the fabric rope wise in the machine (total 10
nozzles and 100 mtrs to be loaded in each nozzle)
Dolly Winch
Dolly Winch
Activity Description
Get the programe for the machine from the shift
Supervisor
WLS No: PHP/11
WORK LOAD DETAILS SHEET
G Shifts A
Dissolve the chemical(DTC:800 gms) in the dosing
tank and dose the same in the machine
Fill water in the m/c, perform cold washing and
drain the water (machine element)
Fill new water, pass chemical (DTC:500 gms),
increase the temperature upto 50 degree celcius,
hold at 50 degree celcius and drain the water
(machine element)
Fill new water in the m/c,increase the temperature
upto 50 degree celcius and perform two hot wash
(machine element)
Stitch the ends of all the ropes to make them
endless rope of the fabric
Note all the piece detail rope wise and process
parameter in the register in a given format
Set the machine parameter or program number on
the screen and ensure its occurance of the same
Get the chemical issue slip from the shift supervisor
and give the issue slip to chemical substore and get
the chemical from there for the machine
Drain water and fill new water (machine element)
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Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Scouring area
Work Centre Present Manpower 2 2 - -
Machine Name Proposed Manpower 2 2 - -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
B C
PHP
Dolly Winch
Dolly Winch
Activity Description
WLS No: PHP/11
WORK LOAD DETAILS SHEET
G Shifts A
12
1 1 70.00
13
1 1 54.00
14
1 1 54.00
15
1 1 33.00
16 1 1 9.00
17
2 1 59.64 119.3
18
1 1 4.24 4.2
19
1 1 14.43 14.4
20
1 1 4.65 4.7
A 319.72
B 13
C 361.28
D 900
E 40.14%
F 2
G 40.14%
Drain water and fill new water and do cold wash
(machine element)
Rest & Relaxation Allowances ( % )
Fill new water in the m/c,increase the temperature
upto 50 degree celcius,hold at 50 degree celcius and
drain the water (machine element)
Fill new water in the m/c,increase the temperature
upto 50 degree celcius,hold at 50 degree celcius and
drain the water (machine element)
Unload the material in trolley
Locate the empty trolly with hole and unload the
matrial in it
Total Workload ( in man minutes )
Remarks:
Drain out the water
Basic Workload per Shift ( in man minutes)
After reciving the goods at delivery end put the tag
of dry for next process on the trolly and deliver it to
the designated place of drying process and cover the
trolly with polythene sheet
Net Available man-mins
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Open the fabric rope with the help of ropeopener in
an trolly with polythene sheet
Dissolve the chemical (DTC:300 gms) in the
dosing tank and dose the same in the
machine,increase the temperature upto 50 degree
celcius, hold at 50 degree celcius and drain the
water (machine element)
Take the material in rope form to the rope opener
and stitch the end with the previous cloth
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Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section Scouring Section
Work Centre Present Manpower 2 2 2 -
Machine Name Proposed Manpower 2 2 2 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
1 1 4.59 4.59
2
1 2 4.83 9.66
3
2 2 45.23 180.92
4
1 2 2.57 5.14
5
1 2 8.77
6
1 2 9.50 19
7 1 6 25.00
8 1 2 15.76
9 1 6 25.00
10
1 2 15.76
11
1 2 26.14 52.28
12
2 2 44.65 178.6
13
2 2 4.65 18.6
14
2 2 8.92 35.68
A 504.47
B 13
C 570.05
D 900
E 63.34%
F 2
G 63.34%
Rest & Relaxation Allowances ( % )
Locate the empty trolly with hole and unload the
material in it
After unloading the goods put the tag of dry for next
process on the trolly and deliver it to the designated
place of drying process and cover the trolly with
polythene sheet
Clean the machine filter before starting of any batch
Roll from one roll to another (machine element)
Present Utilisation(%)
Proposed Manpower per shift
Roll from one roll to another (machine element)
Total Workload ( in man minutes )
Jumbo Jigger
Activity Description
Drain water and fill new water (machine element)
Get the programe for the machine from the shift
Supervisor
Locate the goods to be run on the machine (2500 mtr
at a time)
Basic Workload per Shift ( in man minutes)
B
Drain water and fill new water (machine element)
Shifts
Fill water in the m/c (4000-5000 ltr) (machine
element)
Jumbo Jigger
Stitch leader cloth with the main fabric and load the
material on the machine
Get the chemical issue slip from the shift supervisor
and give the issue slip to chemical substore and get the
chemicals(hydro,caustic,soda ,catsol and BTC) from
there for the machine and dissolve the chemical in the
dosing tank and dose the same in the machine
Set the machine parameter or program number on the
screen and ensure its occurance of the same
Remarks:
WLS No: PHP/12
WORK LOAD DETAILS SHEET
G C
Proposed Utilisation(%)
Take chemical (acid) and add, roll from one roll to
another for one round
PHP
Net Available man-mins
A
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Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani
Department
Section
Scouring Section
Work Centre Present Manpower 1 1 1 -
Machine Name Proposed Manpower 2 2 2 -
Sl.
No
Crew
Size
Freq/
Shift
Basic
Time
(Mins)
Total
Time
(Mins)
1
1 1 5.27 5.27
2 1 1 3.27 3.27
3
2 11 9.81 215.82
4
2 11 0.83 18.26
5
1 11 45.00
6
2 11 10.21 224.62
7
1 11 2.12 23.32
8
1 11 5.72 62.92
9
1 11 1.03 11.33
10
1 11 3.55
11
1 11 3.21 35.31
12
1 1 3.85 3.85
A 603.97
B 13
C 682.49
D 450
E 151.66%
F 2
G 75.83%
Net Available man-mins
After complition of the cycle take out the goods from
the machine in a cleaned trolly
Remarks:
Start the m/c and do hydro extraction (machine
element)
After reciving the goods at delivery end put the tag
of dry for next process on the trolly and deliver it to
the designated place of drying process and cover the
trolly with polythene sheet
Locate the empty trolly in the process house for next
fabric
Tie the fabric with the old fabric already hung and
run the m/c till it passes to the other side of the
reopenor where it is coming after being reopened
Start reopening (machine element)
Basic Workload per Shift ( in man minutes)
Rest & Relaxation Allowances ( % )
Total Workload ( in man minutes )
C
Present Utilisation(%)
Proposed Manpower per shift
Proposed Utilisation(%)
Hydro Extraction
Hydro Extractor
Activity Description
Bring on more trolley and place polythene sheets into
it
Get the programe for the machine from the shift
Supervisor
Locate the goods to be run on the machine
PHP
Close the cover of the m/c and note the details in
theregister
Take the trolley to reopenor
Load the goods in piled form in Hydro extractor as
per the program given (300 mtr at a time) (machi