PRODUCTION PROCESS

Factory dynamics:
 Productivity
 Work station
 Raw material
 Routing
 Job
 Throughput
 Capacity
 Raw material inventory (rmi)
 Finished goods inventory (fgi)
 WIP (work in process)
 Cycle time
 Lead time
 Bottle neck
 SMV(standard minute value)

Productivity=output/input x100

Work station:
The work station is a collection of one or more or manual
station that perform identical or same.

Routing:
Routing describes the sequence of work station pass
through by a part .routing start at a raw materials & end
at finished goods inventory.
Job:
A job refers to a se of physical matter that traverse a
routing.routing is going to during that material that is
called job.

Throughput:
Average output of a production process per unit time this
is the throughput.

Capacity;
Capacity is the upper limit of the throughput.
120 pcs/hour
140 pcs/hour throughput is the average production.
160 pcs/hour capacity.

RMI:
Cutting RMI(stock point) sewing.
The stock point before start of the production or sewing
this is called RMI.
Inventory at the end of the production.

WIP:
The inventory between the start & end pointof a product
routing this called WIP.
WS→end

→WIP

WS→start.
Fraying-being out of yarn.

CT:
From cutting to after finishing how times are need this is
called cycle time.
CT=3-4 days non washable garments.

Lead time :
Upto delivery from order.

Bottle neck:
140 pcs/hour productivity
60 pcs/hour→bottle neck
80 pcs/hour productivity.

Production:
Production is defined as a process or procedure to
transform a set of input into output having the desired
utility & quality.production process is a value addition
process.

input→ transformation process→output(goods & service)

man
machine
materials
information money
energy.
Productivity:
Productivity is the ratio of output & input.
ERP=enterprise resource planning.

Assemble operation:
To joint a all part of the garments part to part by
stiching.

Rule:

The following data were given for one sample day:

Output=250 pcs
Sewer present=40 workers
Sewer absent=5 workers
Non-sewer present=8 workers
Non-sewer absent=4 workers
Normal working hour=8 hours
Overtime=2hours
Actual working hour=10 hours
Material required=1800 yds
Energy consumption=$400 per day.
Calculate all productivity index?

Labor productivity:

Direct labor productivity=volume of output/direct labor

input
=volume of output/direct labor input x W.D x W.H
=250/40 x 1 x 10
=0.625 pcs/mn-hour
indirect labor productivity=volume of output/indirect
labor input x W.D x W.H
=3.125 pcs/mn-hour

total labor productivity=volume of output/total labor

input
=250/(40+8) x 1 x 10
=0.521 pcs/mn-hour

machine productivity=volume of output/machine input

=0.555 pcs/mn-hour

energy productivity=volume of output/energy input

=250/400
=0.625 pcs/$

material productivity=volume of output/mtl input

=250/1800
=0.148 pcs/yds

1)109.5m
=109.5m x 1.0936=………yds
2)109.5m
=109.5 x 39.37/36=……….yds.
 1000 micro meter=1 mm
 10 mm=1 cm
 100cm=1 m
 2.54 cm=1 inch
 36inch=1 yds
  91.44 cm=1 yds
 1760 yds=1 mile
 453.6 gm=1 lb
 1 kg=2.204 lb
 840 yds=1 hank
 120 yds=1 lea
 39.37 inch=1 m
 1 cone=500 m yarns
 1 cone=18000 inch yarns
 knit=110-520 gsm

Line balancing(cuff make):-

Capacity=no of operator x absentism factor x W.H x 60 x

L.E

Absentism factor=100-% of absent/100

Line target=capacity/ttl smv

T.W.S(theoretical work station)=line target/individuak
target
A.W.S(actual work station)

%of balancing loss= €(A.W.S-T.W.S)/ € T.W.S x 100

individual target=60/individual smv

remark=T.W.S/A.W.S x 100
cuff make:
S.L no operator Smv
01 Cuff rolling .12 min
02 Cuff run st .45
03 Cuff twining .1
04 Cuff forming .13
05 Cuff top st .38

Total SMV=1.18 min,% of absent=10%,line

efficiency=80%,layout the m/c.,balancing the
time,calculate time balancing.
Capacity=10 x 100-10/100 x 1 x 60 x 80/100 min
=432 min
line target=432/1.18
=366 pcs/hr

SL operato sm Individual T.W.S A.W.s Aws- Remark

no r v target tws
1 .12 500 .732 1 .268 73.2
2 .45 133 2.751 3 .249 91.7
3 .1 600 .61 1 .39 61
4 .13 461 .793 1 .207 79.3
5 .38 158 2.316 2 -.31 115.8
6
=7.202
 Fig:line balancing sheet.

Individual target=60/.12
For cuff rolling=500 pcs/hr
Tws=366/500

% of balancing loss=.268+.249+.39+.207/7.202 x 100

remark=tws/aws x 100

SMV calculation:
Time study sheet:
No Sel1 EL1 SEL2 EL2 SEL3 EL3 SEL4 EL4
of sec
obs
1 0 3 3 30 33 3 36 3
2 39 3 42 22 64 3 67 3
3 70 2 72 23 95 2 97 -

SMV=bt+m/a+r/a
BT=ot x rating factor
M/A=machine allowance
R/A=relaxation allowance
Individual target=60/individual smv

Rating factor=obs rating/100

M/a=9% of BT
BT for machine operation=OT for m/c operation x rating
factor
R/A=15% of BT
OT per cycle=€EL1/no of obs+€EL2/no of obs+€EL3/no
of obs+€EL4/no of obs
=8/3+75/3+8/3+6/2
=33.34 sec
say rating=80

BT=ot x rating factor

=ot x obs rating/100
=26.67 sec
m/a calculation-

BT for m/c operation =25 x 80/100

=20 sec
for single needle lockst m/c allowance=9%

M/a =9/100 x 20=1.8 sec

R/A =15/100 x 26.67
=4.004 sec
SMV=26.67+1.8+4.004
=32.474 sec
=32.474/60 min=0.541 min
individual target=60/0.541
=110.90
=111 pcs/hr

INCENTIVE CALCULATION:

Monthly payment=G.S+O.T hour x O.T rate +incentive

Incentive=1/2 (€earned hour-available hour) x basic rate

Earned hour=SMV x ttl production/60 hr

Available hr=monthly working hr

Gross salary of a worker is=2200(including basic,house

rent,medical=150,house rent 40% of basic)his monthly
over time=48 hr,production =25000 pcs,smv of the
operator is=.65 min,ttl working day is 26
Calculate his monthly payment?

Incentive calculation:

Basic rate calculation-

G.S =basic+house rent+medical
2200 =basic+hr+150
basic+hr =2200-150
basic +hr =2050
basic + 40% of basic=2050
basic+40/100 basic =2050
basic =2050 x 100/140
basic =1464.28
basic rate =basic/W.D x W.H
=1464.28/26 x 8
=7.04 tk/hr
OT rate =2 x basic
=14.08 tk/hr
earned hr =.65 x 25000/60
=270.83
=271 hr
available hr=W.D xW.H +ot rate
=26 x 8 +48
=256 hr
incentive =1/2 x 150.6
=52.8
monthly payment=2200+48 x 14.08 +52.8
=2928.64
monthly payment=2928.64

The end