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APPC ASSIGNMENT-3
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INDUSTRY VISIT REPORT

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VISHAL KUMAR, APOORV JAITLY

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HIMANSHU SHEKER, SURAJ KEDIA

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Daily target
Efficiency Target per day Target per hour
100 575 72
90 518 65
80 460 58
70 403 50
60 345 43

They work at efficiency of 60% so target per day is 345 pcs

On the day of visit they produced 321 pcs in the line , less than the daily
i.e 345 pcs

WIP CALCULATION

Number of Operation Description WIP

Operations
1 Front Panel Marking for Pintuck
Making

3 Pintuck Making 24

1 Neck Frill Fold 4

1 Neck Frill Shell and Lining Run 6

Stitch

1 Side Panel Attach 3

1 Shoulder Attach at Shell 3

1 Shoulder and Side Panel Overlock 2

1 Shoulder attach at Lining with 12

Piping Joint

2 Neck and Armhole Run Stitch 4

1 Neck Frill Gather Making 16

2 Neck Frill Attach 6

1 Placket Attach 5
 1 Placket Finish with Edge Stitch 4

1 Side Attach at Shell and Lining 7

1 Side Pintuck Seam at Lining 8

1 Sleeve Opening Fold 5

1 Sleeve Gather Making 13

1 Sleeve Attach 11

1 Armhole Overlock 4

1 Armhole Top Stitch 3

1 Neck Binding 8

1 Neck End Close 4

1 Lining Bottom Fold 6

TOTAL WIP
158

WIP FOR THE DAY - 158

Material flow
The pieces flow in form of a bundles with manual labour (helper) in one direction
with with an end-line inspection. So it is a one-way flow of materials.

OPERATOR ALLOCATION
Operators are allocated by industrial engineers and supervisors on the basis of the
skill & efficiency of the operators. They dont have any formal skill matrix sheet. it
takes 3-4 hours for line balancing depending upon the complexity of style.

Sewing line capacity (In pcs)

No. of sewing machines in the line= 32
Workers absence percentage of that line= 5%,
Daily working hours of that factory= 10
Line efficiency of that factory= 60%,
Standard allowed minutes (SAM) for the style= 34

Sewing line capacity= [{(32* 10 *60) 5 %} * 60%] / 34

= 443 pcs

CMT CALCULATION
SMV of the garment= 34 mins

No. of operator used= 33

Salary of each operator= Rs. 9,000/month

=Rs. 346/day

= Rs. 34.6/hour

LABOUR COST PER MINUTE= Rs.0.58

CMT COST= ( SAM of the garment * minute cost of the labour)/ (line efficiency %)

CMT of the garment= 34 * 0.58/ 60 %= Rs.32.68

Causes of lowest efficiency in Layout Plan

- No skill inventory chart

- Lack proper training & improvement programme.

- Lack of compliance issues.

-Operators absenteeism.

- More allowance time.

- Machine break down.

- Failure in Time study calculation.

-Improper supervising of sewing line etc.

Steps needed to improve efficiency

- Conducting motion study and correcting faulty motions.

- Hourly operator capacity check.

- Use best possible line layout by skill matrix

-Reduce line setting time.

-Improve line balancing

-Use work aids, attachments, guides, correct pressure foots and folders.

-Continuous feeding to the sewing line.

- Training for Line supervisors. .

-Setting individual operator target.

- Eliminate loss time and off-standard time.

-Real time shop floor data tracking system.

- Inline quality inspection at regular interval.

-Operator motivation.

- Plan for operators Incentive scheme

FORMS THAT ARE FILLED FROM THE LINE