OPTIMIZATION OF MAN-MACHINE RATIO IN GARMENT INDUSTRY

Transcription

1 Internatinal Jurnal f Human Resurces Management (IJHRM) ISSN(P): ; ISSN(E): Vl. 3, Issue 1, Mar 2014, IASET OPTIMIZATION OF MAN-MACHINE RATIO IN GARMENT INDUSTRY AMBIKA B 1 & JOSEPH REGY 2 1 Lecturer, Institute f Technlgy fr Textile, Garment & Fashin Design, Bahir Dar, Ethipia 2 Prfessr, Natinal Institute f Fashin Technlgy, Bangalre, Karnataka, India ABSTRACT Effective use f machines and manpwer is essential in manufacturing f apparel prducts fr ensuring high prductivity investment frm available resurces in tday s cmpetitive business envirnment. It is thus crucial t establish ptimal man-machine rati t gain high resurce utilizatin and prfitable utput. KEYWORDS: Man Machine Rati, Garment Industry, Prductivity INTRODUCTION Apparel industry has an imprtant place in the Indian ecnmy, mainly due its cntributin t exprt and creatin f emplyment fr millins f peple. In spite f internatinal cmpetitin, Indian apparel industry has been able t imprve its exprt perfrmance. The dmestic market in India is grwing at a steady pace. Studies frm NIFT and Mckinsey have identified lw prductivity as ne f the majr stumbling blck in imprving the cmpetitiveness f the industry. The tp fifteen exprting cuntries f apparel cntributed t abut % f the ttal apparel exprt. As we can see in the table 1, the tp fifteen apparel-exprting natins including the develped cuntries and develping cuntries. China and Hng Kng (nly fr dmestic exprt), Turkey with US$ 13.6 billin wrth exprts tpped amng the western cuntries, fllwed by Bangladesh (US10.9$), India (US$ 10.9). As regards wrlds tp fifteen imprting cuntries f apparel, Eurpean unin tped with US$ billin wrth imprts in the year as shwn in the table united states, Japan, Russian federatin, Hng Kng, china are fllwed frm EU. Table 1 Leading Exprters and Imprters f Clthing, 2008 (Billin Dllars and Percentage) Share in Wrld Annual Percentage Value Exprters Exprts/Imprts Change China a Eurpean Unin (27) extra-eu (27) exprts Hng Kng, China dmestic exprts re-exprts Turkey Bangladesh b India editr@iaset.us

2 60 Ambika B & Jseph Regy Table 1: Cntd., Viet Nam b Indnesia Mexic a United States Thailand Pakistan Tunisia Cambdia b Malaysia a Abve Imprters Eurpean Unin (27) extra-eu (27) imprts United States Japan Russian Federatin b Hng Kng, China retained imprts Canada c Switzerland United Arab Emirates b Australia c Krea, Republic f Nrway Mexic a, c China a Singapre retained imprts Turkey Abve 15 d a Includes significant shipments thrugh prcessing znes b Includes Secretariat estimates. c Imprts are valued f..b. d Excludes retained imprts f Hng Kng, China. Surce: Internatinal trade statistics 2008, WTO As we can see the cmparisn is made fr few prducts where we have cnsidered the same. I am ging t cmpare the prducts named cttn truser fr wmen rank-25, knit shirt fr wmen- rank-22, cttn truser fr men rank-17, MMf cats fr wmen rank 13, MMF nn knit shirts fr men rank-8, ther cttn apparel rank-7, in this reprt based n man-machine rati. editr@iaset.us

3 Optimizatin f Man-Machine Rati in Garment Industry 61 Table 2: Tp Apparel Imprts by the US: Hw India Ranks vis-à-vis its Neighburs Surce: Ecnmic and plitical weekly April 2004 Figure 1 Prductivity is a measure f utput frm a prductin prcess, per unit f input. Fr example, labr prductivity is typically measured as a rati f utput per labr-hur, an input. Prductivity may be cnceived f as a metric f the technical r engineering efficiency f prductin. As such, the emphasis is n quantitative metrics f input, and smetimes utput. Wrkfrce prductivity is the amunt f gds and services that a labrer prduces in a given amunt f time. It is ne f several types f prductivity that ecnmists measure. Labr prductivity can be measured fr a firm, a prcess r a cuntry. Measured labur prductivity will vary as a functin f bth ther input factrs and the efficiency with which the factrs f prductin are used (ttal factr prductivity). S tw firms r cuntries may have equal ttal factr prductivity (prductive technlgies) but because ne has mre capital t use, labur prductivity will be higher. Output per wrker crrespnds t the "average prduct f labur" and can be cntrasted with the marginal prduct f labur, which refers t the increase in utput thse results frm a crrespnding (marginal) increase in labur input Operatr prductivity = vlume f utput/direct labr input (vlume) Example: peratr prductivity = 2000 shirts per shift/100 peratr = 20 shirt per shift editr@iaset.us

4 62 Ambika B & Jseph Regy Factrs Affecting Prductivity Level f technlgy Prduct style, price pint and prductin vlume Training f wrkfrce and management Mtivatin level f wrkfrce and management Awareness f ptimal prductivity level High rate f nn-first quality prductin Labr turnver and absenteeism Prductin scale Lead time Industrial engineering Labr relatins Prductin Quality per Year This is the target prductin quantity per year when prduct specified in prduce drawing is manufactured in accrdance with the cnditin mentined in this dcument. Wrk Days per Year 300 days are set fr wrk days per year. Prductin Quantity per Shift The prductin quantity per line X the number f lines X 1 shift = the prductin Quantity per shift. Frmula 1 The prductin quantity per shift = Wrking time per shift X the number f wrker Standard ttal peratin time * Each data can be calculated by applying (Frmula 1) Number f (Prductin) Line Cutting Sectin This is the line where the cutting carries ut, where the number f peple required cutting fr a particular prtin and the target prductin is calculated Sewing Sectin This is the line where actual sewing peratin is made. The number f lines varies depending n item. This calculates an apprpriate number f persns per line, and indicates the required number f lines fr target prductin editr@iaset.us

5 Optimizatin f Man-Machine Rati in Garment Industry 63 quantity. When there are multiple lines, anther methd culd be cnsidered, namely autmatic machines, fusing press machines, special equipment etc. are treated as cmmn equipment being separate frm sewing sectin. Treating them as cmmn equipment will increase the peratin rate f each equipment. This is judged frm an apprpriate prductin quantity f each equipment. Finishing Sectin This is the line where finished prducts by sewing sectin are cmplemented and refrmed by supplementary wrks (remval f thread fray, hand stitching f buttns, hemming ), inspectin, ff-press, irn etc. When there are multiple sewing lines, ff-press machines and special equipment are cmmn equipment, and finished prducts may be intensively prcessed. Number f Shift The number f shifts per day. Wrking Time per Shift 8 Hurs are set fr wrking time per shift. (8 hurs=480 minutes) Number f Wrker The number f persns required in the sectins f sewing line and finishing line. The indirect persns such as supervisrs, persns fr transprtatin are nt included. The number f persns listed here is calculated subject t the wrkers wh are highly qualified in each wrk f peratin flw. Frm (Frmula 1) Frmula 2 The number f wrkers = Prductin quantity per shift X standard ttal peratin time Wrking time per shift Operatin Time This is the required ttal peratin time fr cmpleting a garment spent in sectins in sewing line and finishing line. This time includes time allwances, nt including the time f ALT r VAR. TIME ALLOWANCE..This is the time irregularly spent fr the incidents against the regular time spent fr prduct peratin during wrking time, such as arrangement f prducts, thread change, transprtatin (transfer) f prducts, discussin fr wrk, restrm, negligence etc. Unit is minute. Daily Prductivity (Sewing (sectin) nly) This is the daily prductivity by direct sewing peratin per wrker. In case the design changes, peratin time in peratin flw varies. The prductivity changes accrdingly. Daily prductivity = Prductin quantity per shift Number f sewing (sectin s) wrker editr@iaset.us

6 64 Ambika B & Jseph Regy RESEARCH DESIGN Prject Title Optimizatin f man-machine rati fr garment industry Statement f Prblem: Effective use f machines and manpwer is essential in manufacturing f apparel prducts fr ensuring high prductivity investment frm available resurces in tday s cmpetitive business envirnment. It is crucial t establish ptimal man-machine rati t gain high resurce utilizatin and prfitable utput. Objectives Optimizatin f man-machine rati Achieving high prductivity investment frm available resurces T gain high resurce utilizatin and prfitable utput. METHODOLOGY Study f the prductivity f factries. Operatin breakdwn fr selective style in manufacturing department s that prcess flw and manpwer requirement fr each culd be established. Cmprehensive detailing f manpwer requirement fr each peratin and establishing a standard rati based n the study The cmparisn wuld invlve the fllwing Manpwer requirement and Machinery cmparisns fr each peratin Operatin prductivity cmparisn chart Cmparisn f prfitable utput n the machines and manpwer. Analysis f man and machine rati. Determinatin f ptimized man-machine rati fr factries. Implementatin and Suggestins. Scpe T analyze the requirement f the garment industry and suggest the best pssible infrastructure in terms f machineries and manpwer keeping the prductivity in mind, s that the prpnent gets the best man machine rati. Therefre it has a very gd scpe f setting up a plant f apparel industry with apprpriate man machine rati. Limitatins Assuming same style is running in the whle factry. Optimizatin is carried ut nly in the prductin department. editr@iaset.us

7 Optimizatin f Man-Machine Rati in Garment Industry 65 Type f Research: Descriptive research Sample Size: Wven industry = 3, Knit s = 3 Tl fr Cllectin f Data The cllectin f data is dne thrugh direct interview and telephnic cnversatin with the cncerned peple. By visiting varius Wven & Knits garment industry METHOD OF COLLECTING DATA Bth primary and secndary data is cllected. Primary Data During visit t garment industry by bservatins, the primary data like prducts prcess sequence, machines used fr particular peratin, n f machines, n f peratr, skill matrix, learning perfrmance and ptimizatin f man-machine rati is carried ut by using thrugh bservatin, recrding & cllectins. Secndary Data Bks, magazines Varius publicatins f the central, state & lcal gvernments. Reprts & publicatins f varius assciatins cnnected with business. Methd f Analysis Cmparisn with the standard manuals Statistical analysis f man and machineries required fr the industry. Analysis thrugh charts. Prject Wrk Factry 1 Cmpany Prfile Table 3 Industry ABC industry pvt ltd Unit-10 Type Manufacturing& Exprting Specializatin Wven s Established 1978 Annual revenue 80 millin USD Emplyees Machine 500+ Step 1: Calculatin f Man Machine Rati Table 4 On Rll 10% Sewing Man: Machine Factry Type Lines Manpwer Absenteeism Machine Rati ABC unit-10 wven editr@iaset.us

8 66 Ambika B & Jseph Regy Step 2: Break up f n Rll Manpwer Table 5 TIPL-10 Manager 2 Quality Assurance 9 Sampling 8 IE 9 Trainnee 9 Dispatch 7 HR 10 Fabric 6 Maintance 8 Stre 5 Other 8 Cutting Sectin 130 Sewing Sectin 670 Finishing 283 Step 3: Break up f Prductin Sectr CUTTING SEWING FINISHING Table 6 Number f peratrs 72 Number helpers 36 Number f checkers 9 Number f supervisr 13.5 Number f peratrs 441 Number helpers 81 Number f irners 108 Number f checkers 27 Number f supervisr 13.5 Number f peratrs 63 Number helpers 162 Number f irners 45 Number f supervisr 13.5 Step 4: Time Study fr Cutting Annexsure-1a Step 5: Time Study fr Sewing Annexsure-1b Step 6: Time Study fr Finishing Annexsure-1c Step 7: Prductivity Calculatin fr Shirt Manufacturing Sectr Step 7a: Cutting Prductivity Table 7 CUTTING Sl. N Particulars TPIL-10 Target Number f machines 8 2 Number f peratrs 8 3 Number helpers 4 5 Number f checkers 1 6 Number f supervisr Duratin f wrk shift 480 editr@iaset.us

9 Optimizatin f Man-Machine Rati in Garment Industry 67 Step 7b: Sewing Prductivity Step 7c: Finishing Prductivity Step 8 Table 7: Cntd., 8 SAM f Shirt (sewing) Average daily utput (per shift) Operatr Prductivity Prductivity Effeciency /Operatr Ttal Labur Prductivity(pcs per shift) Machine Prductivity 87.5 Table 8 SEWING Sl. N Particulars TPIL-10 Target Number f machines 49 2 Number f peratrs 49 3 Number helpers 9 4 Number f irners 12 5 Number f checkers 3 6 Number f supervisr Duratin f wrk shift SAM f Shirt (sewing) Average daily utput (per shift) Operatr Prductivity Prductivity Effeciency /Operatr Ttal Labur Prductivity(pcs per shift) Machine Prductivity 15.5 Table 9 Sl. N Finishing Particulars TPIL-10 1 Number f machines 15 2 Number f peratrs 7 3 Number helpers 18 4 Number f irners 5 6 Number f supervisr Duratin f wrk shift SAM f Shirt (sewing) Average daily utput (per shift) Operatr Prductivity Prductivity Efficiency /Operatr Ttal Labur Prductivity(pcs per shift) Machine Prductivity 5.5 Cmparisn f Each Operatin with JUKI Annexure -1d Based n SAM, n f MANPOWER, n f MACHINE editr@iaset.us

10 68 Ambika B & Jseph Regy Step 9: Implemented Results in ABC-10 Table 10 SAM MANPOWER MACHINES TARGET ACHIVED Fr Allcatin f manpwer,with the help f skill matrix is carried ut Annexsure-1e Few attachments where used like the Autmatic garment stacker Cllar flder Cuff flder Sleeve placket hlder Autmatic pcket seeker Results Table 11 SEWING Sl. N Particulars TPIL-10 Target Number f machines 40 2 Number f peratrs 40 3 Number helpers 6 4 Number f irners 0 5 Number f checkers 3 6 Number f supervisr Duratin f wrk shift SAM f Shirt (sewing) Average daily utput (per shift) Operatr Prductivity Prductivity Effeciency /Operatr Ttal Labur Prductivity(pcs per shift) Machine Prductivity 20 If it can happened fr 1 line then fr the factry IMPLEMENTATION RESULTS Man: Machine rati Table 12 Factry Type Lines On Rll 10% Sewing Man: Machine Manpwer Absenteeism Machine Rati(E/F) ABC unit-10 wvens ABC unit-16 wvens editr@iaset.us

11 Optimizatin f Man-Machine Rati in Garment Industry 69 Table 13 Operatr Prductivity Prductivity Effeciency /Operatr Ttal Labur Prductivity(pcs per shift) Machine Prductivity Factry-2 Cmpany Prfile Table 14 Industry XYZ apparel Pvt,ltd Type Manufacturing& Exprting Specializatin Wven s Annual revenue 80 millin USD Emplyees 800+ Machine 300+ Step 1: Calculatin f Man Machine Rati Table 15 On Rll 10% Sewing Man: Machine Factry Type Lines Manpwer Absenteeism Machine Rati(E/F) XYZ apparels pvt wvens Step 2: Break up f n Rll Manpwer Step 3: Break up f Prductin Sectr Table 16 XYZ Apparels Pvt Ltd Manager 2 Quality Assurance 5 Sampling 10 IE 10 Trainnee 10 Dispatch 5 HR 10 Fabric 5 Maintance 7 Stre 5 ther 8 Cutting Sectin 99 Sewing Sectin 453 Finishing 201 Table 17 CUTTING SEWING FINISHING Number f peratrs 54 Number helpers 24 Number f checkers 12 Number f supervisr 9 Number f peratrs 312 Number helpers 72 Number f irners 30 Number f checkers 30 Number f supervisr 9 Number f peratrs 48 Number helpers 114 Number f irners 30 Number f supervisr 9 editr@iaset.us

12 70 Ambika B & Jseph Regy Step 4: Time Study fr Cutting Annexsure-2a Step 5: Time Study fr Cutting Annexsure-2b Step 6: Time study fr Cutting Annexsure-2c Step 7: Prductivity Calculatin fr Shirt Manufacturing Sectr Step 7a: Cutting Prductivity Step 7b: Sewing Prductivity Table 18 CUTTING XYZ Apparels Sl. N Particulars Pvt Ltd TARGET Number f machines 9 2 Number f peratrs 9 3 Number helpers Number f checkers Number f supervisr Duratin f wrk shift SAM f Shirt (sewing) Average daily utput (per shift) Operatr Prductivity Prductivity Effeciency /Operatr Ttal Labur Prductivity(pcs per shift) Machine Prductivity 83.3 Table 19 SEWING XYZ Apparels TPIL-10 Particulars Pvt Ltd Sl. N Target Number f machines Number f peratrs Number helpers Number f irners Number f checkers Number f supervisr Duratin f wrk shift SAM f Shirt (sewing) Average daily utput (per shift) Operatr Prductivity Prductivity Effeciency /Operatr Ttal Labur Prductivity(pcs per shift) Machine Prductivity Step 7c: Finishing Prductivity Table 20 FINISHING XYZ Sl N Apparels Particulars Pvt Ltd 1 Number f machines 8 2 Number f peratrs 8 editr@iaset.us

13 Optimizatin f Man-Machine Rati in Garment Industry 71 Table 20: Cntd., 3 Number helpers Number f irners Number f supervisr Duratin f wrk shift SAM f Shirt (sewing) Average daily utput (per shift) Operatr Prductivity 8 11 Prductivity Effeciency /Operatr Ttal Labur Prductivity (pcs per shift) Machine Prductivity 7.9 Step 8: Cmparisn f Each Operatin with JUKI Cmparisn f Each Operatin with JUKI Annexure -2d Based n SAM, n f MANPOWER, n f MACHINE Step 9: Suggestin Table 21 SAM MANPOWER MACHINE TARGET ACHIVED Fr Allcatin f manpwer, with the help f skill matrix is carried ut Annexsure-2e Few attachments where used like the Use f Autmatic garment stacker Use f Cllar flder Use f Cuff flder Use f Sleeve placket hlder Use f Autmatic pcket seeker Use f Prper allcatin f manpwer Use f Training prgram fr peratrs Used f Mtivatin fr the peratrs like the incentive schemes based n the perfrmance Use f barcde system t track the prduct and als peratr prductivity can be traced easily Use f cmfrtable ergnmically designed chairs fr the peratrs Playing f pleasant music after the lunch break Educatin abut the prduct,wrk If they face sme injustice then there shuld be a suggestin bx t drp r cunseling shuld be carried ut every mnth during the leisure time editr@iaset.us

14 72 Ambika B & Jseph Regy If it can reduce in the 1 line then in the whle factry CONCLUSIONS Table 22 Operatr Prductivity Prductivity Effeciency /Operatr Ttal Labur Prductivity(pcs per shift) Machine Prductivity Table 23 Factry Type Lines On Rll 10% Sewing Man: Machine Manpwer Absenteeism Machine Rati(E/F) XYZ wvens XYZ wvens Fr Allcatin f manpwer, with the help f skill matrix is carried ut Few attachments where used like the Use f Autmatic garment stacker, Use f Cllar flder, Use f Cuff flder, Use f Sleeve placket hlder, Use f Autmatic pcket seeker, Use f Prper allcatin f manpwer, Use f Training prgram fr peratrs,used f Mtivatin fr the peratrs like the incentive schemes based n the perfrmance, Use f barcde system t track the prduct and als peratr prductivity can be traced easily and few thinks like Use f cmfrtable ergnmically designed chairs fr the peratrs, Playing f pleasant music after the lunch break, Educatin abut the prduct,wrk, If they face sme injustice then there shuld be a suggestin bx t drp r cunseling shuld be carried ut every mnth during the leisure time. By ding the abve things the peratr prductivity increase apprximately by 1/4 %, Prductivity Efficiency /Operatr by 1%, Ttal Labr Prductivity (pcs per shift) by 1.4% and machine Prductivity by 1.4% and verall man machine rati reduced frm 2.33 t REFERENCES 1. Surce: Internatinal trade statistics 2008, WTO 2. Surce: Ecnmic and plitical weekly April Gldratt Case study 1; Intel Assembly and Test manufacturing 5. Case study 2; Clark Eczne s Garment Industry: The Need t Upgrade 6. Technical Educatin and Skills Develpment Authrity. (2000). Clark Eczne s Garment Industry: The Need t Upgrade. Retrieved July 22, 2005 frm the Wrld Wide Web: 7. Article f Rajesh Bheda 8. Managing Prductivity in the Apparel Industry by Rajesh Bheda 9. Surce: editr@iaset.us