Wolkite University College of

Engineering and Technology Department of Garment

Engineering intern ship report at yonis garment plc.

Project Title-Productivity Improvement Through Using Work

Aid.

Prepared By- Muluken Adane

Id no-ENGR 288/05

Submitted to-Inst Melkamu. W

 PRODUCTIVITY IMPROVEMENT THROUGH USING WORK AID

Declaration

I am 4th year garment engineering department student in wolkite university institute of textile
garment and fashion technology. I have completed in yonis garment plc located in saris (Addis
industry zone), Addis Ababa. And all source data and pictures used while compiling this report
get fully acknowledged and I approve this by my signature.

Name: Muluken Adane

Signature: -----------------------------------------------.

Date of submission: 07 /01/ 2009E.C

Approved by

Company production manager: Mr. Worku

Signature: -------------------------------------------------

Wolkite university institute of textile, and fashion design technology

Academic advisor: Inst. Melkamu

Signature: --------------------------------------------------

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 PRODUCTIVITY IMPROVEMENT THROUGH USING WORK AID

Acknowledgement

First and foremost, I want to praise god for helping me in this report and in general for the
knowledge and strength he offered me in my life time. Special thanks deserve to wolkite
university, industry linkage office, garment engineering department head and instructor my
mentor Mr. Melkamu, for giving me the chance to have an experience on the practical work
and getting better skills with theoretical knowledge.
It is also my pleasure to thank Mr. Worku (production manager of a company), for his speedy
answer to my request. And also his day to day supervision, sharing his experience & advice in
my future endeavor and I would like to thank all the workers of the company.
Especially I want to mention my heartfelt thanks to Mr. Solomon debebe (administration and
finance head of a company) and also to other staff members for their supervision and guidance.
I appreciate, Mr. Dereje (cutting room supervisor) for her good response, and I would like to
appreciate Mr. Tesfaye (maintenance head of the company) for his sociability and his open
heart advice Mr. Banda (company assistance) for his professional advice, also my campus
friends, all the daily professionals together with their assistants, who provided me invaluable
guidance and advice.
Finally, I would like to give my heartfelt appreciation to my family and friends for their
encouragement, tolerance and endless support throughout my stay in the internship program.

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EXECUTIVE SUMMARY
This final internship report covers my four months’ report when stay in yonis garment plc from
March 2016 up to June 2016. It is a clear fact that the knowledge of garment engineering
cannot be upgraded without practical experience in each field of the subject matter. This paper
is a written report about the internship program. This report is about the back ground of our
hosting company including its history and major achievements, our overall internship
experience, tasks and the procedures we followed, the practical and theoretical knowledge we
gained including the challenges we faced while performing those tasks. The contents of the
report have been divided into three chapters and the topics covered include the company
background, our overall internship experience, and the benefits we gained from the program,
our conclusions and recommendations for the company. To help anyone reading this report
better understands the discussed topics and ideas, figurative illustrations and samples of works
and different report formats which are attached at the middle of the topics. Generally, this
internship practice enlightened me with different theoretical and practical knowledge.

Chapter one is about back ground of my hoisting company. Here brief history of the company;
its vision, mission, main products of the company suppliers, customers, machineries and
utilities and other important information of the company are included.

Chapter two discusses about a project work which I have done on productivity improvement
by using work aids. The project contains project title, project statement, objective of the project,
methodology, identified problems and their solutions, conclusion and recommendations.

Chapter three presents about my experience and my work tasks I performed during the four-
month internship program. There are points which has been facing when I am performing my
work tasks what measures I have taken to those problems and benefits I have gained from my
internship program. The benefits are explained briefly in this chapter.

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Table of Content Page

Declaration................................................................................................................................. i
Acknowledgement ....................................................................................................................ii
Executive Summary ............................................................................................................... iii
List Of Abbreviation,Tables And Figures ............................................................................. v
1.1 Brief History Of The Company (Company Profile): ...................................................... 1
1.1.1 Vision................................................................................................................................ 1
1.1.2 Mission ............................................................................................................................. 1
1.1.3 Objective .......................................................................................................................... 1
1.1.4 Work Force ...................................................................................................................... 1
1.1.5 Strategies .......................................................................................................................... 1
1.2 Organizational Structure: ................................................................................................. 2
1.3 Available Machines In Yonis Garment Plc: .................................................................... 3
1.4 Work Flow Of Activities: .................................................................................................. 4
1.5 The Main Products: ......................................................................................................... 8
Abstract ................................................................................................................................... 10
2.1 Introduction ...................................................................................................................... 11
2.3objectives ............................................................................................................................ 14
2.3.1 General Objective ......................................................................................................... 14
2.4 Methodology ..................................................................................................................... 15
2.6 Result And Discussion ..................................................................................................... 23
2.7 Recommendation.............................................................................................................. 25
2.8 Conclusion ........................................................................................................................ 26
2.9 References ......................................................................................................................... 27
3.1 Internship Experience ............................................................................................. 28
3.2 Benefits I Gained From Internships ........................................................................ 28
3.2.1. Practical Skill ....................................................................................................... 29
3.2.2. Theoretical Knowledge ........................................................................................ 29
3.2.3. Garment Problem Solving Skill ........................................................................... 29
3.2.4. Team Playing Skill ............................................................................................... 29
3.2.5. Leadership Skill ................................................................................................... 29
3.3. Limitation Of The Project ...................................................................................... 29

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LIST OF FIGURES Page no

Fig 1. 1 Yonis Garment Plc………………………………………………………………....1
Fig 1.2 Cutting Section……………………………………………………………………...6
Fig 1.3 Sewing Section……………………………………………………………………...7
Fig 1.4 Finishing Section……………………………………………………………………8
Fig 1.5 Product Image……………………………………………………………………….8

LIST OF TABLES
Table 1.1 machine list……………………………………………………………………….3
Table 2.1 calculation of SAM or SMV Through time study………………………………………16-22

LIST OF ABBREVIATION

 Smv ……………….... Standard Minute Value

 Hr. …………………. Hour
 Wip …………………Work in Progress
 N’t …………………...Not
 No …………………. Number
 Opr…………………...Operation
 Pkt………………….... Pocket
 Pbs…………………...Progressive Bundle System
 S/N…………………...Serial No
 M/C…………………...Machine
 Dhu…………………...Defects Hundred Unit
 Fl.……........................Flat Lock
 Dn……………………. Double Needle
 Ol3……………………Three Thread Over Lock
 Sn…............................Single Needle
 Qty……………………Quantity
 Yg……………………Yonis Garment
 Plc ……………………Private Limited Company

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 CHAPTER ONE
1.1 Brief history of the company (company profile):
Yonis garment plc is a privately owned company. It owned and established by Solomon debebe
and Annita fabbari in 2003 E.C and registered under the commercial laws of the federal
democratic republic of Ethiopia.
Yoni s garment plc. Is located in saris (Addis industry zone), Addis Ababa. The factory is
equipped with state of art production facilities acquired from the most reputable manufactures
of the world such as juki, japan with over 138 sewing machines.

1.1.1 Vision
The vision is to become an exemplary organization in both the local and international apparel
markets.

1.1.2 Mission
The mission is to realize our vision by generating a reasonable return to the shareholders
through proper utilization of resources and continuous customer satisfaction.

1.1.3 Objective
 To produce high quality wearing apparels that can compete in the local market.
 To attract capital and technological know-how.
 To generate reasonable profit.

1.1.4 Work force

At full capacity currently, the factory has 125 employees

1.1.5 Strategies
 Develop a strong customer relationship.
 Engage in a continuous product development endeavors.
 Devise and implement methods of reducing cost of production without affecting quality of
products. Provide continuous personnel training and capacity building.

Fig 1.1 yonis garment plc

 PRODUCTIVITY IMPROVEMENT THROUGH USING WORK AID

1.2 Organizational Structure: Managing

director
Auditory

Departmen
t Manager

Manageme
nt
representati
ve

Human Planning Marketing Technical

Cutting Quality
Resources and cost and Finance Maintenan
Departmen Departmen
Departmen control Merchandi Manager ce Manager
t Manager t Manager
t Manager manager zing
Manager
Responsibility of functional area
Management representative-managing all the department supervisors
Finance Dep’t- controls and supply payment custom clearance/cost analysis
Maintenance department- controls over all activates and managing the maintenance cycle
Marketing Dep’t-control goals and study cost/price of product and promotion of products.
Managing Director - controls the overall activities of the company.

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1.3 Available Machines in Yonis garment plc:

Yoni’s Garment Plc. has taken the most care in selection of appropriate technology to the
Ethiopian condition. After evaluating the offer made by different technology supplies the
company bought Japanese manufactured sewing and cutting machines and equipment.

No Mode Description Qty

1. DDL8300N 1- needle lock stitch 63

2. LH-3128SF 2-needle fix bar machine 8

3. LH- 3168GF 2-needle split bar heavy m/c 2

4. Mo-6743S-1D6-40H 6- thread Inter lock machine 40

5. LK-1850U bar tack machine 3

6. MS-1190D 2-needle feed of arm 4

7. LBH-781U button hole machine 3

8. MB-373 NSOOS button stitch m/c 3

9. DFB-1412-P 12-needle m/c 4

10. 629 8” east man Cloth cutter 4

11. WX-8803F flatbed flat lock m/c 19

12. RX-9803CL 3-needle cylinder beds m/c 7

13. Accessories Attachment fordiff m/c 17

14. Cutting machine Straight knife 3

15. Cutting machine End cutter 1

16. Finishing machine Electric iron with steam 5

17. Finishing machine Electric hand iron 3

Table 1.1 machine list

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1.4 Work Flow of Activities:

Initial input for activities to start performing customer’s sample order is a sample order sheet
which prepared by our Merchandiser. As I mentioned early this sample order sheet holds
technical file that holds the required information then we go to check the pattern and all
information on it e.g. if we face some problem on it immediately we inform to our
Merchandiser to communicate with the customer and to send another pattern After the pattern
is received with suitable information to our Job we going to start our work immediately when
we finished our job the design checked again comparing with the given customer’s original
pattern.
Likely if there is no customer’s pattern to use we develop the pattern as per the given
specification sheet or as per the original sample given. Most of the time they didn’t make a
pattern because there is no pattern design development section.
Then the next activity is checking a material in the store if the customer didn’t send his/her
own material to make the sample but many times the customer send his own material in Yonis
garment plc. If we can’t find the material, we discuss with Merchandising Department if
possible to use the available resource or not.
Merchandising Division can advise to wait or making the sample with the available resources.
So we wait until we get the material from our Merchandising. But if approved to use locally
available resources immediately cut and make the sample with similar material then check in
all aspect.
Receipt of sample order sheet
A copy of sample order sheet is received from merchandising division. It includes the list of
what the customer wants and do not wants including the specification sheet and also other
special customer requirements.

Fabric inspection
If the customer supplies fabric no need of checking or inspection. Otherwise there is a need of
inspection.
Evaluation of the original sample
If the customer provides original sample to follow sample department evaluates every part of
this original sample.

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Factory work flow from store to warehouse

Store room

Cutting room

Sewing room

Inspection

Trimming

Packaging
z

Finished goods

There is no design or pattern Department in the factory

Grading - if the buyer requires different sizes, so should be grade as s, m, l, XL, and xxl.

Marker making –marker is a thin paper which contains all the components for different sizes
for a particular style of garments. This department is the main department where the pre-
production operations are carried out. In this department the marker maker makes marker plan
efficiently for different fabric according to different fabric characteristics. For carrying out this
activity there are marker makers and supervisors.

Fabric spreading –spread the fabric on table properly for cutting. There are two spreading
table, after the required fabric is brought into the cutting section from the stores.

The number of lays depends upon the requirement of the sewing and the number of the garment
to be produced. After the fabric is laid, if the fabric is knitted its directly cut because its already

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marked by chalk, but in case of others the marker paper is spread on the lay where the pattern
is already drawn and it is cut to know the consumption of the fabric for the garment.
The spreading operators carry out aligning operation on the side of the lay by considering the
way in which they improve their speed and also way in which they minimize wastage at the
start and at the end of the roll.
Cutting –cut fabric according to marker dimension. The other operation is carried out in cutting
department. The cutting operator cut the fabric for production by considering ways of using
fabric in a very saved and minimized consumption. In this section, the cutting of interlining is
carried out without any fault by using straight knife cutting machine and end cutter.

Fig1.2 cutting section

Sorting & bundling –sort out the fabric according to size and for each size make in individual
bundles. All the parts are moved to the numbering area by the helper.
Numbering supervisor verifies the number of parts in an order and clears the number according
to lot (batch) wise. With the help of sizes the numbering operators stick all the parts serially.
Details of the numbering of parts and the lot number are entered in the numbering register.
Checking of parts is carried out after numbering the parts if stains or any other damage occur,
cross stickers "x" will be placed on the damaged place and those parts are replaced.
Sewing –assemble a full garment. This is where your precision comes in to play in great deal.
You have an experienced work ship to skillfully handle any stitching complexities that this
stage requires. These workers make sure their timely delivery is met with best accuracy. You
are high-end sewing machines and workmen form a mesh to offer variety of stitching type and
styles.
This department contains the most complex activity of the garment manufacturing process of
sewing. It is one of production output of garment factory. The sewing process involves a
number of sewing operators, who deal with for the assembly of different sub assembly
operations,

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The lines also have a line supervisor, for supervising the sewing operator to work according to
the engineer direction. The sewing process carried out according to the sub and main assembly
work.
The sewing process starts after receive of cut parts in bund. For this bund form is then
distributed to the sewing operator by line supervisor. The distribution for each specific operator
is according to the layout of the sewing line which is made by the engineer depending on the
styles and order there are also in line quality control operator, who are responsible for the
identification any fault during the specific main assembly operation. In this section has
5sewingline&72sewingmachine,about 82% of them juki type of different varieties includ
ing: single & three, four & five thread over lock machines, flat locks, two & three needle feed
of the arms,& different specialized machines.

Fig 1.3 sewing section

Ironing &finishing-treated with steam ironing & also several finishing processes are done for
example extra loose thread cutting. In this department ironing and packing operation are carried
out. It is the final output of garment prepare for packaging. For the purpose of making a proper
packing from part of work wear are ironed in this section. An operator in this department insert
pin the folded garment in the invisible place of plastic bags. For the purpose of improving the
quality of folding template are prepared. After products are processed the last part of production
is pressing and packing pressing could be done with electric hand iron on the ironing tables
and there are 5 electric iron with steam finishing machine. Packing can be done manually. A
high degree of attention is played by the packing operator.

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Fig 1.4 finishing section

Final inspection-should be approved as initial sample. In sewing area each line has inspection;
inline and off line inspection. Inline inspection is before garment making random inspection
inside sewing area; of line inspection is 100% inspection after garment production out of
sewing area., and sort the control garment in two first, second quality and repairable garments.
Spot cleaning, this can be reprocessed and reclassified as first or second quality garment again.

Packing –treated by poly ethylene bag.

Cartooning –after packing, it should be placed in cartooning for export.

Dispatching –ready for export.

1.5 The Main products:

 Polo shirt (for local)
 T- shirt (for local)
 Children’s wear (for local)
 Chef coat, chef vest, chef pant (for export)
 Over wear (for local)

Fig 1.5 Product image

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The main customers

 Mulat plc
 Degefaw plc
 Cintas plc

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CHAPTER TWO

PROJECT WORK ON PRODUCTIVITY IMPROVEMENT

THROUGH USING WORK AID

ABSTRACT

Working aid is an essential part of any Garments Sewing Section. Sewing work aids adversely
affect the production and product quality and also help to decrease production cost. In this
study, the manufacturing sequence of different types of bottoms, types of machines used for
each process, the number of workers used in a sewing line, working hours of the garments,
SMV and daily production of polo shirt was enlisted and recorded as well. That data was
collected while the polo shirt was manufactured by using work aid and also when that polo
shirt was manufactured in the sewing line without using sewing work aids. As a result, it was
concluded that garment production was hugely improved by the use of garment sewing work
aid.

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2.1 INTRODUCTION
Productivity is a measure of the efficiency and effectiveness to which organizational resources
(inputs) are utilized for the creation of products and/or services (out puts). Productivity
measurement is both a measure of input utilization and an assessment as to whether or not in
put utilization is growing faster than output.

Work aids are additional devices that can be added to basic sewing machines such as folders,
guides and pressure foots. If work aids are used effectively operation cycle time can be reduced
many fold than existing cycle time.

Work aids of sewing machines means additional working parts which are attached with the
general sewing machines to increase productivity, to reduce faults and to increase quality. work
aids can be fitted with machine easily.in a statistic it was seen that, a sewing machine works
with 80% time and 20%time for fabric handlings.to reduce this wastage in industrial production
of garments work aids are required.

The work aids that are used during sewing operations can be categorized in a number of
different ways and they vary in the aspect of their overall purpose that they emphasize some
otter greatly increased the speed of working in a situation where quality is already satisfactory.
Others give a very little improvement in productivity but the great accuracy of sewing. In terms
of their function, the commonest ones are used for guiding or folding materials for trimming
threads and other components from garments and for stacking the work after sewing. In terms
of their method of working some are purely mechanical, some operate pneumatically, some are
photoelectric and some are electronic, some are built into the machine such as a special
monitor, some are a variation of a normal machine part such as a special presser foot, and some
are a completely separate added part. Guides are used where sewing must take place in a certain
position on a garment, usually a certain from a raw edge as in a conventional superimposed
where a narrow item such as a lace or braid must be correctly positioned on a garment and
where one garment part must be correctly placed on another such as a patch pocket on a shirt
skirt or trousers. In their simplest form, they are edge guides, formatting some kind of physical
barrier to the fabric being joined together. The extra machine parts which may attach to speed
up the production and improved quality in the sewing machine are called work aid.

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2.2 LITERATURE REVIEW

Definition:

Production: is the process used to transform material in puts (raw materials, semi-finished
goods, sub-assemblies) and immaterial inputs (plans, ideas, in formation, knowledge) in to
goods or services. Basically resources are used are used in this transformation process is to
create a goods or services which has value and contributes to the utility of individuals or
groups.

Productivity: Is a measure of the efficiency and effectiveness to which organizational

resources (inputs) are utilized for the creation of products and/or services (out puts).
Productivity measurement is both a measure of input utilization and an assessment as to
whether or not in put utilization is growing faster than output.

Work aid: Is the extra machine parts which may attached to speed up the production and
improved quality in the sewing machine are called work aid. Work aids is one type of
productivity improvement techniques in apparel manufacturing industry.

These are some kinds of time saving devises that facilitate operator to perform their work
effectively with less effort. If work aids are used effectively operation cycle time can be
reduced many fold than existing cycle time. In new and small factories where there is no
experienced technical person (maintenance, I.e. personnel or production manager) generally
not aware about the usage and availability of work aids. So their operators sew garment free
hand. Labor productivity is comparably higher for the factories that widely use work aids than
those who do not use work aids for the similar products. Folders and attachments are also very
helpful in producing consistent stitching quality. On the other hand, work aids, guides and
fixtures reduce operator’s movement and weight lifting.

The requirements for work Aids

The additions which can be made to basic sewing machines are many and they come under the
general term work aids. Work aids are device which are built into machines, added to them
afterwards, attached alongside or made use of in whatever ways a resourceful engineer can
device to simplify an operation, reduce handling, improve productivity, Improve or maintain
quality standard, reduce training time and Minimize fatigue for the operator. Many work aids
have been developed to facilitate the use of basic equipment and make it more adaptable to

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specific operations. Carefully selected work aids can often produce significant savings. Work
aids can be purchased, created by research and development departments, or developed by
engineers, mechanics, and technicians on the production floor. Work aids may be used in all
types of operations including cutting, sewing, and finishing, but they are most widely used in
the sewing room because of the accuracy and labor intensity required. Work aids that are used
during sewing operations can be categorized in a number of different ways and they vary in the
aspects of their overall purpose that they emphasize. Some offer greatly increased speed of
working in a situation where quality is already satisfactory. Others gives very little
improvement in productivity but great accuracy of sewing. In terms of their function the
commonest ones are used for guiding or folding materials, for trimming threads and other
components from garment and for stacking the work after sewing. Some work aids depend on
manual involvement by an operator. Others may operate mechanically or by pneumatics or
electronics. These include separate devices, attachments, and machine options.

Separate devices positioned in the workstation are frequently used to facilitate operations and
for materials handling. These may include bundle trucks or carts, stands for positioning
bundles so they are easily accessible to the operator's grasp, bins or racks for easy disposal of
parts when sewing is completed, or snips for cutting thread. Clamps are helpful in maintaining
orderly stacks of parts.

Folding devices are used to position trim just in front of the needle. The folder, which is an
open-ended funnel, causes the edges to turn to the underside as it passes through to the needle.
The exact position of the attachment on the cloth plate may be a factor in how bias strips or
other trims are applied.

Attachments are primarily mechanical work aids that can easily be added or removed from
the machine or work station according to the requirements of a particular sewing operation.
Attachments may be stationary, swivel, slide, or pivotal in order to be engaged and disengaged
from the area of operation. Attachments often assist an operator in guiding, positioning,
folding, and regulating the materials during the sewing operation.

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2.3OBJECTIVES
2.3.1 General objective
 The overall objectives of this project are to increase the productivity by minimizing
operation cycle time through work aid in sewing section.

2.3.2 Specific objective

 Improve the quality of garments.

 Reduce the work load-on operator.
 Reduce the time for handling.
 Control the garments quality.
 Get familiar with work aids.
 Know the different functions of the work aids.
 Know the use of work aids in garment making sequences.

Problem statement

 In yonis garment plc used some kinds of work aids in the sewing section and also there
is absence of work aids. Due to this problem the sewing operators sew garments with
free hand (without different work aid). And this problem highly affects production of
the company. When I see this I have decide to make this project in yonis garment plc.

Scope of project

 To improve the productivity of yonis garment plc specifically in sewing section.

Significant of the project

(Benefit)

 Simplify an operation, reduce handling, improve productivity, Improve or maintain

quality standard, reduce training time and Minimize fatigue for the operator.

Beneficiaries- owner of the company, employer’s, researchers and also me.

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2.4 METHODOLOGY
The most popular methods & use of collecting data for project are; Data Collection is a
process through which data is collected and prepared. It forms the basis of project data
collection are:
Primary Data

 Observation:

Observation is another useful method to collecting a lot of data. It also means you are not
reliant on people having to give the information and their time. Observation can be used to
measure things such as efficiency of operators and their performance. This is used to gate the
real data.

 Interviews:

Interviews can give you more detailed data and can be ideal to scratch beneath the surface of
an issue. Although fairly time consuming and not always completely relevant data or
information (there may be various parts of an interview that are never used), it is still a useful
method of research. And to ask considered the problem of system and write on my document.

Secondary Data

 Internet accesses:

Internet accesses are another useful method to collecting general a lot of data. It also
another great way of collecting data.

 Hand out:
To collecting data for the project work we check or refer handout.

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2.5 DATA ANALYSIS

I used different type of Materials and equipment’s for this project. Such as

1) Fabric -98% cotton & 2% elastic

2) Garment Sewing Work Aid (Types of equipment)-Such as Plan Guide, guide,
compensating pressure Foot, Stitching Jig, Specialized pressure foot, Light, Folder has
been used for this project.
3) Machines-There are different types of machine I Used, such as SNLS,4thread over
lock,3thread over lock and cover stich has been used for this project.

Calculation of SAM or SMV through time study

TIME STUDY
CUSTOM
ER name GARMENT TYPE-
Mr. Mulat polo shirt
STYLE time cycle
avera
operation no ge averag
breakdow operat m/c cycl cycl cycl cycl cycl cycl secon e cycle rat basic allowan
n or type e1 e2 e3 e4 e5 e6 d minute e time ce smv
Fusing 70
placket 120 124 125 112 128 % 25%
fusing 70
2
m/c %
70
121.8 2.03 % 1.421 0.355 1.78
Placket
preparatio 1 iron 70
n 26 18 19 22 23 18 21 0.35 % 0.245 0.061 0.31
Mark
placket 1 pencil 70 0.418
line 35 40 39 31 42 28 35.83 0.5972 % 06 0.105 0.52
Binder
binder
preparatio 1 70
m/h
n 25 26 23 18 19 24 22.5 0.35 % 0.245 0.061 0.31
Placket 70 0.418
attach1 1.8 52 53 40 48 43 0.5972 % 06 0.105 0.52
SNLS
Placket 70 0.262
attach1 37 36 37 42 40 29 38.23 0.375 % 5 0.066 0.33

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Tear
placket 1 scissor 70 0.299
line 24 28 26 29 22 25 25.67 0.4278 % 44 0.075 0.37
Tack, turn
& make 70
box 2 SNLS 67 68 76 71 73 79 0 % 0 0 0
70
73 75 62 73 7 85 67.42 % 0 0 0
4th
Join
1 overlo 70 0.476
shoulder
ck 40 44 52 38 33 38 40.83 0.6806 % 39 0.119 0.6
Join collar
tip to 70 0.772
bodice 2 SNLS 72 71 72 64 59 74 1.1042 % 92 0.193 0.97
70
48 52 74 72 72 65 66.25 % 0 0 0
3th
Collar
1 overlo 70 0.264
attach
ck 25 22 22 25 24 18 22.67 0.3778 % 44 0.066 0.33
3th
Binder
1 overlo 70 0.307
attach
ck 24 28 29 33 21 23 26.33 0.4389 % 22 0.077 0.38
upper
placket 1 SNLS 70
run stitch 29 25 22 22 24 22 24 0.4 % 0.28 0.07 0.35
under
placket 1 SNLS 70 0.375
top stitch 31 32 35 36 29 30 32.17 0.5361 % 28 0.094 0.47

Upper
Placket 1 SNLS 70 0.348
top stitch 31 32 35 22 29 30 29.83 0.4972 % 06 0.087 0.44
Size label 70 0.338
1 SNLS
attach 31 37 18 28 29 31 29 0.4833 % 33 0.085 0.42
Close
collar 70
binder 2 SNLS 31 37 39 35 30 38 0.59 % 0.413 0.103 0.52
70
34 35 40 38 35 42 35.4 % 0 0 0
4th
Join cuff 1 overlo 70 0.418
ck 37 38 34 36 39 31 35.83 0.5972 % 06 0.105 0.52
Sleeve 70 0.333
4th
attach 55 58 1.2 1.5 1.02 55 28.62 0.477 % 9 0.083 0.42
2 overlo
70 0.690
ck
49 62 65 62 58 59 59.17 0.9861 % 28 0.173 0.86
attach cuff 70 0.864
2 SNLS
tip 57 59 65 62 85 82 74.08 1.2347 % 31 0.216 1.08

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 PRODUCTIVITY IMPROVEMENT THROUGH USING WORK AID

70
74 93 83 72 78 79 % 0 0 0

Side seam 70 0.864

4th
joining 71 73 40 62 78 79 1.2347 % 31 0.216 1.08
overlo
ck 70
54 83 63 83 71 62 68.25 0 % 0 0 0

Bottom 70 0.674
cover
hemming 50 1 72 75 77 58 0.9639 % 72 0.169 0.84
2 stitch
m/ch 70
54 51 62 63 72 59 57.83 0 % 0 0 0
Make
button 1 B/H 70 0.342
hole 28 29 33 31 29 26 29.33 0.4889 % 22 0.086 0.43
botton PENC 70 0.184
1
marking IL 15 14 13 16 18 19 15.83 0.2639 % 72 0.046 0.23
Button 70 0.233
1 B/A
attach 24 18 21 19 18 20 20 0.3333 % 33 0.058 0.29
70 1.802
Trimming
125 247 122 135 145 153 154.5 2.575 % 5 0.451 2.25
SCIS 70
3
OR % 0 0 0
70
% 0 0 0
TOTAL
TIME 35 1182 18.99 16.6

Table 2.1 polo shirt sewing operational break down and SMV with sewing work aid. Various
kind of sewing work aid has been used in during garments production.

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TIME STUDY

STYLE time cycle

average
operation no machine cycle cycle average cycle basic
breakdown operator type 1 cycle2 cycle3 4 cycle5 cycle6 second min rate time allowance SMV
Fusing
placket fusing 120 112 118 122 128 136 123 25%
2
m/c 2.04 70% 1.43
0 1.75

Placket
1 iron
preparation 26 18 19 22 23 18 21 0.34 70% 0.24 0.059 0.29

Mark placket
1 pencil
line 58 39 46 35 30 29 39.5 0.35 70% 0.25 0.061 0.31

Binder binder
1
preparation m/h 7 6 8 6 8 11 7.67 0.66 70% 0.46 0.115 0.58
Placket
attach1 25 37 40 28 35 33 33 0.13 70% 0.09 0.022 0.11
SNLS
Placket
attach1 45 58 120 90 59 58 0.55 70% 0.39 0.096 0.48

Tear placket
1 scissor
line 23 30 25 28 29 31 52.3 0.87 70% 0.61 0.153 0.76

Tack, turn &

make box 2 SNLS
54 52 37 40 33 47 43.8 0.73 70% 0.51 0.28 0.64
1 1.2 65 62 63 58 41.7 0.7 70% 0.49 0.122 0.61

4th
Join shoulder 1
overlock 37 30 41 33 46 29 36 0.6 70% 0.42 0.105 0.53

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 PRODUCTIVITY IMPROVEMENT THROUGH USING WORK AID

Join collar
tip to bodice 2 SNLS 75 73 72 64 49 45 1.12 70% 0.78 0.196 0.98
48 52 64 73 72 65 67.2 70% 0 0 0

3th
Collar attach 1
overlock 36 38 32 45 46 45 40.3 0.67 70% 0.47 0.118 0.59

3th
Binder attach 1
overlock 26 23 22 22 24 28 24.2 0.4 70% 0.28 0.07 0.35

upper placket
1 SNLS
run stitch
27 24 24 31 25 20 25.2 0.42 70% 0.29 0.073 0.37

under placket
1 SNLS
top stitch
24 25 22 20 21 22 22.3 0.37 70% 0.26 0.065 0.33
Upper
Placket top 1 SNLS
stitch 20 25 31 22 22 28 24.7 0.41 70% 0.29 0.072 0.36
Size label
1 SNLS
attach 21 25 26 24 24 24 24 0.4 70% 0.28 0.07 0.35

Close collar
binder 2 SNLS 62 60 63 67 67 1.13 0.91 70% 0.64 0.159 0.8
55 62 56 53 55 55 54.7 0 70% 0 0 0

4th
Join cuff 1
overlock 39 30 39 40 45 42 39.2 0.65 70% 0.46 0.114 0.57

Sleeve attach 4th

2 1.1 1 1.2 1.5 1 55 10.1 0.17 70% 0.12 0.03 0.15
overlock
99 63 60 50 58 1.2 55.2 0.92 70% 0.64 0.161 0.81
attach cuff
2 SNLS
tip 57 54 41 45 48 48 48.8 0.81 70% 0.57 0.142 0.71

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 PRODUCTIVITY IMPROVEMENT THROUGH USING WORK AID

53 54 41 45 48 51 48.7 0.81 70% 0.57 0.142 0.71

Side seam
4th
joining 82 56 95 82 62 60 0.98 70% 0.69 0.172 0.86
overlock
49 45 46 43 46 41 58.9 0 70% 0 0 0

Bottom cover
hemming 2 stitch 89 69 77 75 60 58 1.02 70% 0.71 0.179 0.89
m/c 58 54 1 75 60 59 61. 0 70% 0 0 0

Make button
1 B/H
hole 40 39 33 35 36 35 36.3 0.61 70% 0.42 0.106 0.53
botton
1 PENCIL
marking 15 14 13 16 18 19 15.8 0.26 70% 0.18 0.046 0.23

Button attach 1 B/A

24 24 20 19 18 20 20.8 0.35 70% 0.24 0.061 0.3
Sleeve
1 B/T
tacking 24 20 19 21 21 21 21 0.35 70% 0.25 0.061 0.31
Trimming 2.5 70% 1.75 0.438 2.19

3 SCISOR 0 70% 0 0 0

150 0 70% 0 0 0
TOTAL
TIME 1246 21.1 14.8 18.4

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 PRODUCTIVITY IMPROVEMENT THROUGH USING WORK AID

Table 2.2 polo shirt sewing operational break down and smv for without sewing work aid. any
kind of sewing work aids has not been used in during garments production.

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2.6 RESULT AND DISCUSSION

Table shows the total SMV taken for each garment to complete the process of operation.

Product type Smv(min)value Smv (min) value Variation of SAM

With sewing Without sewing (B-A)=C
Work aid(A) Work aid(B)
Polo shirt 16.6 18.4 1.8

Table2.3 Variations of SMV for with sewing work aid and without sewing work aid in Sewing
Section for polo shirt.

From the above table, it is seen that SMV of the polo shirt produced using sewing work aid and
without using sewing work aid. As a result, the garment of SMV is lower than the same polo
shirt produced without using work aid.

SMV MIN VALUE

18.4

16.6

Diagram 1. Comparison of SMV variation of with and without sewing work aid

Product type No.of Working Efficiency Calculated Calculated

operator Hours production production
With sewing Without
work aids sewing work
aids
Polo shirt 26 8 70% 526 475

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 PRODUCTIVITY IMPROVEMENT THROUGH USING WORK AID

Table 2.4 it is seen that Sewing works aid production of polo shirt higher than without sewing
work aid production.

Production per day=no of operators*working hour*efficiency/smv

With outwork aids =26*480*0.7/18.4 =474.7=475piece/day

With work aid =26*480*0.7/16.6=526.26=526piece/day

PRODUCTION PER DAY

526
475

Diagram 2. Comparison of Production of polo shirt Per Day with and without Work Aid

From the above diagram, it is seen that SMV of the polo shirt produced using work aid is lower
than the same polo shirt produced without using work aid. As a result, the calculated production
of the polo shirt of is higher than the same polo shirt produced without using work aid. The
difference of daily production with and without using work aid was 51piece/day on which was
huge. Work aid ensures a better quality and increase the productivity of a garment
manufacturing process Step. Productivity means the ratio between output and input.

Productivity= output/input

Production with using work aid produces 526 piece/day with 26 operators. Therefore, 1operator
makes 20 pieces/day. Productivity ratio is 1person to 20 pieces. Daily production without using
work aid produces 475 pieces/day with 26 operators. Therefore, 1operator makes 18
pieces/day. Productivity ratio is 1 person to 18 pieces. So this show that productivity improve
through using work aid or effects of work aid in garment production.

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 PRODUCTIVITY IMPROVEMENT THROUGH USING WORK AID

2.7 RECOMMENDATION

Generally, I recommend for the company Use different type of work aids used in sewing
machine. If the company use such kinds of work aids can improve the productivity
 Attachments
 Edge Guides
 Folders
 Hemmers
 Latch Back Device
 Stackers
 Slack Feeder
 Motor Rollers
 Presser Foot and
 Separate devices

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 PRODUCTIVITY IMPROVEMENT THROUGH USING WORK AID

2.8 CONCLUSION

In this project you have seen about the possible usage of work aids and their benefits.so
working aid is an important and essential part of any Garment Industry. Working Aid is one of
the most effective sewing tools. In the domestic production of garments, 20% of the time is
wasted for the handling of fabric and other 80% used for sewing. To reduce this wastage in
industrial production of garments work aids required. These work aids are not only used to
reduce the handling time but also used to improve the quality of the garments. The extent of
process control in maintaining the processing parameters at desired level can be reduced
thereby maintaining quality & increasing productivity. For this purpose, this research project
will be very helpful.

Work aid is the suggestive techniques developed in this article cover a comprehensive series
of aspects in minimizing reworks in the sewing section of apparel industries by ensuring quality
production also helps to improve the productivity. Productivity help to reduce the cost of
product and quality is ultimately gives customer satisfaction. Good quality increases the value
of a product or services, establishes brand name, and builds up good reputation for the garment
exporter, which in turn results in to consumer satisfaction, high sales. The project clearly
indicates that by using work aids improve the productivity of yonis garment plc. In this project
you have seen about the possible usage of work aids, their benefits, will make us able to
maintain quality and reduce the wastage of time due to handling of materials.

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2.9 REFERENCES

•Company document.

• Hand out (sewing technology, productivity and work study)

• Improving working conditions and productivity in the garment industry an action manual
edited by Juan Carlos Hiba. Copyright © International Labor Organization first published
in1998.

• Internet (www .Wikipedia com)

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 PRODUCTIVITY IMPROVEMENT THROUGH USING WORK AID

Chapter 3

Benefits from internship experience

3.1 Internship experience

First of all, when I was in the internship I really happy, and I believe that after the internship
program I have something new I can learn new skill, I will have developed my vision there and
I loved my profession, and valuable work experience. My first task was finding an organization
which has some applications which are related with my study/department. when I am finding I
feel that manufacturing companies can give me the valuable work experience and to expand
my theoretical knowledge manufacturing companies are good and to apply the knowledge I
have learned in the class room to real world life.

3.2 Benefits I gained from internships

Internship helps me to get experience in my field of study. I was not sure what I wanted to do
when I graduated. So I thought some real life experience would help me solidify my future
endeavor. Doing internship help me to know more about my field. It also gives me an in depth
analysis of what it really like to work best field of study.
The benefit of internship which I acquired during my internship includes the following.
practical skill
upgrade theoretical knowledge
industrial problem solving
team playing skill
leadership skill
work ethics issues
entrepreneurship skill

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3.2.1. Practical skill

The three and half month internship program benefited me to have practical skill. Example how the production
presses and control in garment industry is performed. I had learned this theoretically in classroom. And I
experienced this practically in my internship program. From now on wards I can plan practically in garment
factories.

3.2.2. Theoretical knowledge

After I have completed my internship program I am able to upgrade my theoretical knowledge. When I was
learning in the class there was many theories which seems me ideal and not true. But, after I had completed
this internship program I have checked that those I have learned in theory are real and are found in the practical
world

3.2.3. Garment problem solving skill

Completing this internship program makes me to identify the garment problems and then how to solve them
if happened.
My internship gave the opportunity to apply some garment problem solving skill learned with in the class
room to real world activity within the industry. It gives me an in-depth analysis of the industrial problems
really and how to solve them.

3.2.4. Team playing skill

Doing internship, me enables me to develop my team playing skill. It enables me working with my colleagues
who have substantial experience within the garment factory. I develop my understanding on my contribution
to the company as a member the group on the entire objective to be succeeded.

3.2.5. Leadership skill

Doing an internship made me to build my confidence and knowledge on leadership skill i.e. I am able work
with my colleague and prior goal of the company and become effective without creating any disagreement
with my colleagues.

3.3. Limitation of the project

 Communication problem
 Not get full information

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