In a garment production unit, making efficiency, product quality, controlling cost, and elimination of waste etc. are very necessary things to remain its position in this competitive world. Therefore Work study and industrial engineering can play a significant role to standardize overall production, reducing waste, improving productivity. Understanding the key terms and ideas related to these disciplines assists manufacturers streamline the operations. After all these article can enhance your ideas with different terms and definitions in these prospect.
Work Study
Work study is a systematic approach used to analyze and improve work methods
and production efficiency. It depends on two major factors those are: Method study & Work measurement.
1. Method Study
It is also known as motion study, method study focuses on improving the way
tasks are performed by eliminating unnecessary movements and optimizing
workflow that means shrinking overall process within a definite way.
a. Process Chart: A graphical
presentation of the sequence of all operations, inspections, and delays or gaps
in a process.
b. Flow Process Chart: Details every movement of materials and workers in a process.
c. Two-Handed Process Chart: A chart showing detailed hand movements to identify unnecessary actions.
d. Therbligs: Basic hand motions identified in industrial engineering, such as reach, hold, grasp, and release.
e. Workstation Layout: The physical
arrangement of tools, materials, and machinery for overall production flow.
2. Work Measurement
Work measurement quantifies the time required for a task to determine labor
standards and production targets.
Standard Time (ST): The time
allowed for a trained worker to complete a whole task under normal conditions
and situations.
Time Study: The process of
recording the time taken for a worker to complete a task.
Performance Rating: A factor used to adjust observed time based on the worker’s
performance.
Normal Time (NT):The observed time multiplied by the performance rating.
Allowance Factor: Additional time added for fatigue, delays, and personal needs.
SAM (Standard Allowed Minute):
The time required to complete a task, including allowances.
Industrial
Engineering Terms
Industrial engineering focuses on designing efficient systems for man, machine,
materials, and processes in garment production.
1. Productivity and Efficiency
Productivity: The ratio of output (garments produced) to input (time, labor, or materials).
Efficiency: The percentage of
standard time achieved in production.
Formula:
Efficiency (%) = (Earned Minutes / Available Minutes) × 100
Line Efficiency: The overall efficiency of a production line, considering all workers and operations.
Man to Machine Ratio: The ratio of
sewing operators to machines used in production.
2. Production Planning and Control
(PPC)
Work-in-Progress (WIP): The number of unfinished garments in the production process.
Takt Time: The time interval in which a product needs to be completed to meet customer demand.
Bottleneck Operation: A process step that slows down overall production due to its longer cycle time.
Lead Time: The total time taken from order placement to product delivery.
Line Balancing: The process of
distributing workload evenly among operators to maximize efficiency.
3. Quality and Standardization
Defects Per Hundred Units (DHU): The number of defects found in 100 garments.
First Pass Yield (FPY): The percentage of garments that pass quality inspection on the first attempt.
Right-First-Time (RFT): The ratio of garments produced correctly without rework.
Standard Operating Procedure (SOP): A set of documented instructions defining the best way to perform a task.
Kaizen: A continuous improvement methodology that focuses on incremental process enhancements.
Lean Manufacturing: A systematic approach to minimizing waste and maximizing value in production.
Six Sigma: A quality control method
aimed at reducing defects and improving process performance.
4. Workload and Capacity Planning
Operator Cycle Time: The time taken by an operator to complete a single unit of work.
Pitch Time: The rate at which garments are completed and moved to the next process.
Capacity Utilization: The percentage of available production capacity being used.
GSD (General Sewing Data): A
predetermined motion-time system used to establish standard sewing times.
5. Cost and Efficiency Analysis
Cost per Garment: The total cost incurred to produce one garment.
Factory Overhead: Indirect costs such as rent, utilities, and maintenance.
Direct Labor Cost: The wages paid to workers directly involved in garment production.
Overall Equipment Effectiveness (OEE):
A measure of how effectively machines and equipment are utilized in production.
Implementation
and Benefits
Understanding these terms is essential for implementing work study and
industrial engineering techniques in garment manufacturing. By applying these
principles, manufacturers can:
a. Improve production efficiency and reduce bottlenecks.
b. Optimize resource utilization and minimize waste.
c. Enhance product quality and consistency.
d. Reduce production costs while maintaining high standards.
e. Train employees effectively and standardize work procedures.
Conclusion
Work study and industrial engineering are fundamental to achieving operational
excellence in garment manufacturing. By applying standardized methods,
optimizing workflows, and leveraging efficiency analysis, manufacturers can
boost productivity, reduce costs, and ensure high-quality products.
Understanding these key terms and their applications allows businesses to stay
competitive in the dynamic fashion industry.
By continuously refining work processes and adopting innovative techniques,
garment manufacturers can create a sustainable and efficient production
environment that meets evolving market demands.
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