Re-engineering of workstations and standardisation of work method at Laguna Clothing Private Limited

By Siva Jagadish K M

Objectives

To develop new workaids Standardisation of Work Stations Standardisation of work Method

Introduction

Need of this project

Increased raw material cost, more
demanding customers, increased

absenteeism, scarcity of man power

only way to maximize the productivity through engineering

Methodology
Select Record Examine Develop Evaluate Define Install Maintain

List of operations selected for improvements

Collar patch iron Collar neck band Front / Back label attach hemming operations Sew collar band to Front / Back Button & collar Button holing operations Collar button hole / Right front hemming button tandem (standing operation) Cuff button hole tandem Ironing & pressing operations Cuff run stitch Sleeve rolling placket

IMPROVEMENTS & DISCUSSION

OLD METHOD (SMV 0.34)

NEW METHOD (SMV 0.19)

The operator productivity is increased to 300 pcs/hr which is 175 pcs/hr earlier.

COLLAR PATCH IRON

Collar Patch Iron Cost vs. Benefit

Cost involved Benefits Difference in SMV = 0.34 0.19 per minute costing = 0.15 min r 1.8/minute 0

minutes saved per month

Benefit per month

5505.882
R 9910.6

COLLAR NECK BAND HEMMING

OLD METHOD (SMV 0.32)

NEW METHOD(SMV 0.14)

operator is able to 400 pcs/hr instead of 188 pcs/hr.

COLLAR NECK BAND HEMMING

Collar Neck Band Hemming Cost vs. Benefit

Cost involved = 450(folder)+ 400 (box) r 850

Benefits
Difference in SMV = 0.32 0.14 = 0.18 min

per minute costing

minutes saved per month Benefit per month ROI

r 1.8/minute
7020 min R 12,636.00 0.07 month

SEW COLLAR BAND TO COLLAR

Place collar bands
Dispose here

Place collar here Place bundle here

SEW COLLAR BAND TO COLLAR

Sew Collar band to Collar Cost vs. Benefit

Cost involved = 385 (stand) r 385

Benefits
Difference in SMV = 0.51 0.48 = 0.03 min

per minute costing

minutes saved per month Benefit per month ROI

r 1.8/minute
734 min R 1,321.00 0.29 month

COLLAR B HOLE / BUTTON TANDEM

Loading / unloading time(3 sec

Machine cycle (4.5sec)

Machine cycle (4.5sec)

Machine cycle (4.5sec)

Machine cycle (3 sec)

Machine cycle (3 sec)

Machine cycle (3 sec)

The loading and unloading time can be matched with machine cycle time

COLLAR B HOLE / BUTTON TANDEM

Cost involved (table) r 2615.00 Benefit per month R 5200.00 ROI 0.5 month

CUFF BUTTON HOLE TANDEM

Loading / unloading time(3 sec

Machine cycle (4.5sec)

Machine cycle (4.5sec)

Machine cycle (4.5sec)

Machine cycle (4.5sec)

Machine cycle (4.5sec)

Machine cycle (4.5sec)

The loading and unloading time can be matched with machine cycle time
Cost involved (table) Benefit per month ROI r 1490.00 R 5200.00 0.29 month

CUFF BUTTON HOLE TANDEM

CUFF RUN STITCH

CUFF TRAY + DISPOSE TRAY + FRONT TRAY

Cost involved (table) Benefit / month R.O.I

r 312.00 r 2,014.00 0.15

SLEEVE ROLLING PLACKET

The SMV for new method is 0.76 and the old method is 0.83.

SLEEVE ROLLING PLACKET

Sleeve Rolling Placket Cost vs. Benefit

Cost involved = 1900 (switch) + etc r 3112

Benefits
Difference in SMV = 0.83 0.76 = 0.07 min

per minute costing

minutes saved per month Benefit per month ROI

r 1.8/minute
1052 min R 1,894.00 0.61 month

FRONT WASH CARE LABEL ATTACH

Place labels here Place fronts here

The SMV for new method is 0.43 and Old method is 0.53

FRONT WASH CARE LABEL ATTACH

The SMV for new method is 0.43 and Old method is 0.53

Front care label attach

Cost involved = 210 (tray) + 492 (side tray) r 702

Benefits
Difference in SMV = 0.53-0.43 = 0.1 min

per minute costing

minutes saved per month Benefit per month ROI

r 1.8/minute
2354 min R 4,238.00 0.17 month

Other work aids developed

Other work aids developed

Other work aids developed

Ironing work stations

Define & standardise work

Collar & cuff Front Back Sleeve Assembly

SUMMARY

Reduction in SMV = 139.7 seconds = 2.33 minutes All operations ROI is below one month
S.no
1 2 3 4 5 6 7

Operation

Old Method
20.4 19.2 30.6 15 105 58.2 49.8

New Method
11.4 8.4 28.8 7.5 55 52.8 45.6

Difference in sec 9 10.8 1.8 7.5 50 5.4 4.2 6 9 6 2 4 4 1.2 16.8 2 139.7

8
9 10 11 12 13 14 15 16

collar patch iron collar neck band hemming sew collar to collar collar button hole / button tandem cuff button hole tandem (6) cuff run stitch sleeve rolling placket front label attach back main label attach split yoke attach premium label attach front button hole front buttoning side seam checking cuff attach kansai (FRONT PLACKET) Total change in seconds

31.8
32.4 28 14 31 31 30 67.2 14

25.8
23.4 22 12 27 27 28.8 50.4 12

SUMMARY- Time savings

S.no
1 2 3 4 5 6

Operation
collar patch iron collar neck band hemming sew collar band to collar collar button hole / button tandem cuff button hole tandem (6) cuff run stitch

kpr line-1 9 10.8 1.8 7.5 50 5.4

kpr line-2 9 10.8 1.8 7.5 50 5.4

kpr line-3 9 10.8 1.8 0 0 5.4

kpr line-4 9 10.8 1.8 0 0 5.4

Jigini 9 10.8 1.8 0 0 5.4

7
8 9 10 11 12 13 14 15 16

sleeve roling placket

front label attach back main label attach split yoke attach premium label attach front button hole front buttoning side seam checking cuff attach kansai (FRONT PLACKET)

4.2
6 9 6 2 4 4 1.2 16.8 2 139.7

4.2
6 9 6 2 4 4 1.2 16.8 2 139.7

0
6 0 6 0 4 4 1.2 16.8 2 67

0
6 0 6 0 4 4 1.2 16.8 2 67

0
6 0 6 0 4 4 1.2 16.8 2 67

Total change in seconds

SUMMARY- Cost Involved

S.no
1
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Operation
collar patch iron
collar neck band hemming sew collar band to collar collar button hole / button tandem cuff button hole tandem (6) cuff run stitch sleeve roling placket front label attach back main label attach split yoke attach premium label attach front button hole front buttoning side seam checking cuff attach kansai (FRONT PLACKET)

kpr line-1

kpr line-2

kpr line-3

kpr line-4

Jigini

0
850 770 2615 2980 936 3112 1404 500 676 500 1360 1360 1230 0 980 19273

0
850 770 2615 2980 936 3112 1404 500 676 500 1360 1360 1230 0 980 19273

0
850 770 0 0 936 0 1404 0 676 0 1360 1360 1230 0 980 9566

0
850 770 0 0 936 0 1404 0 676 0 1360 1360 1230 0 980 9566

0
850 770 0 0 936 0 1404 0 676 0 1360 1360 1230 0 980 9566

cost involved in rupees

Total Cost in rupees

67244

SUMMARY- Productivity
kpr line-1
smv
savings in SMV new smv

kpr line-2
23.29
2.33 20.96

kpr line3
25.37
1.12 24.25

kpr line-4
23.94
1.12 22.82

Jigini
23.76
1.12 22.64

23.29
2.33 20.96

old target
new target increase in productivity pcs/ machinist - old pcs/ machinist - Present diff

1298.41
1442.63 144.22 14.43 16.03 1.60

1298.41
1442.63 144.22 14.43 16.03 1.60

1191.96
1246.84 54.88 13.24 13.85 0.61

2385.96
2502.70 116.74 14.04 14.72 0.69

1272.73
1335.49 62.77 14.14 14.84 0.70

Total increase in productivity per day

523

SUMMARY

Total Investment done - r 67,244

Increase in productivity /day - 523 pcs

% increase in Productivity
Line 1 & 2 Line 3, 4 & Jigini Plant - 10% - 4.5%

Future Scope
Lines can be rebalanced Automation of more operations

Collar run stitch Cuff hem pressing Laser attachments Air jets Main label + Premium label attach

Limitations

Constrained only to formal shirts Some workaids will not be fully utilised as there are major changes in the styles Workaids will change to according to other production system, considered only progressive bundle system Zigs / Profile sewing machines were not able to use for smaller order quantities. Certain operations were not considered due to time limitations

THANK YOU