M

TIME STUDY
LINE # 10

BEFORE IMPROVEMENT TIME STUDY

S.No

Operations

Average

Operation

Operator

c1

c2

c3

c4

c5

time

Average

Name

(sec)

(sec)

(sec)

(sec)

(sec)

(sec)

(sec)

Cuff
1

Hemming

Sadhna

16

18

20.7

19.4

16.5

18.12

18.12

Cuff Making

Meena

24.4

25.7

24.4

26.1

25.6

25.24

25.24

Collar Profile Sushma

22.2

24.2

21.1

16.5

18.1

20.42

20.42

Sangita

5.3

7.2

18.5

11.3

9.12

10.28

10.28

Collar/
Collar Band
Margin
4

Cutting
Collar

Turning

Jayalakshmi

6.12

5.3

7.1

5.5

6.00

6.00

Cuff Turning

Hemlata

17.4

16

16.9

18.7

17.4

17.28

17.28

Jyoti

11.7

10.6

11.9

9.8

11.7

11.14

11.14

Tara

31.5

30.5

38

33.6

32.4

33.20

33.20

Anita

29.5

34.1

33.3

27.4

28.4

30.54

30.54

Raju

20.3

18.9

25

20.4

23.8

21.68

21.68

Kusum

29.3

27.6

27.6

25.6

28.5

27.72

27.72

Laxmi

9.4

6.2

9.5

11.7

8.76

8.76

Poonam

41.7

35.4

32.6

33.6

30

34.66

34.66

Front Placket
7

Strip joining
Collar Band

Marking
Cuff
trimming and

ironing
Collar

10

ironing
Collar

11

Topstitch
Collar
Marking and

12

Trimming
Collar Band

13

Attachment
Collar Peak

14

Making

Renu

15.3

15.4

16.3

15.1

15.1

15.44

15.44

15

Wash Care

Brahmwati

6.7

6.1

17.1

18.2

10.82

10.82

Label
Attachment
Main Label
16

Attachment

Deepali

29.2

33

23.6

23.3

26.1

27.04

27.04

Reena

22.9

18.9

18.4

15.9

16.5

18.52

18.52

Soni

23.4

23.5

21.1

19.1

22

21.82

21.82

Dinesh

69.4

59.8

78.9

49.2

57.8

63.02

Pushpender

45.5

40.4

38.5

57.6

56.8

47.76

Mohini

22.2

24.1

27.1

25.4

23.8

24.52

24.76

Halima

16.9

18.2

26.7

16.4

20.6

19.76

19.76

Jancy

25.5

33.5

28.4

26.7

25.4

27.90

27.90

Babli

11.3

16.1

12.2

11.3

11

12.38

12.38

Mukesh

51.4

64.1

42.6

59.5

48.4

53.20

Sunita

44.4

40.3

36.8

36.9

37.9

39.26

Anita

25.7

27.7

26.1

29.7

27.8

27.40

27.40

11.0

12.1

Back Pleat
17

making
Front Dart,
pocket

18

marking
Front Placket

19

Attachment
Front Placket

20

Attachment

55.39

Back yoke
21

Attachment
Back Yoke

22

Topstitch
Front Placket

23

Topstitch
Placket
Temporary

24

Stitch
Placket
Temple

25

Making
Placket

46.23

Temple
26

Making
Front Dart

27

Making
Pocket

28

Hemming

Parvati

11.6

12.9

13.3

12.19

12.19

29

Pocket

Seema

28.4

30.9

29.1

34.3

30.4

30.63

30.63

Fusing

Pocket
30

Ironing

Sunil

19.3

19.4

19

19.2

19.1

19.20

19.20

Anu

46.4

48.3

55.9

59.5

59.1

53.84

49.75

42.1

38.7

52.5

52.5

42.5

45.66

Vibha

26.2

23.2

26.8

30.2

24.6

26.20

26.20

Reeta

20

19.9

21.9

24.6

21

21.48

21.48

Ramvati

12.9

9.8

8.9

10.5

12

10.82

10.82

Gudiya

23.7

27.3

23.7

24.2

20.9

23.96

23.96

attachment

Ram kumar

1.72

1.73

1.71

1.72

1.73

1.72

1.72

Cuff

Bhumi

Matching

kumari

21.4

23.3

24.7

26.1

21.2

23.34

23.34

Anju

31.8

34.9

26.4

44.2

28

33.06

Mamta

29.4

34.7

29.1

31.2

38.2

32.52

Bala

49.3

32.6

34.4

31.7

35.4

36.68

Ashok

51.6

50.6

46.5

46.1

42.3

47.42

Pocket
31

Attachment

32
Shoulder
33

attachment
Shoulder

34

Topstitch
Collar

35

Attachment
Back Neck
Temporary

36

stitch
Sleeve
placket

37

38

Sleeve
Temple
39

Making
Sleeve

32.79

Temple
40

Making
Sleeve

41

Attachment
Sleeve

42

Attachment
Armhole

42.05

37.4

43

Attachment

Poonam

69.6

47

62.8

36.6

50.69

44

Armhole

Surender

59.8

70.2

60

60

72.2

64.44

57.56

Attachment
45

Checking

Manju

21.9

22.2

27

19.4

24.2

22.94

Saroj

48.3

86.5

65.3

56.1

62.7

63.78

Pooja

90.2

71.8

69.1

83.3

79.1

78.70

22.94

Side Seam
46

Attachment
Side Seam

47

Attachment

71.24

Sleeve Pleat
48

Making

Maya

20.4

24

21.5

21.2

19.2

21.26

21.26

49

Bottom hem

Lalpari

40.2

40.3

56.2

41.9

48.2

45.36

24.36

Collar
50

Finishing

41.4
Premlata

46.6

39.7

41.8

39.9

41.90

41.90

Urmila

67.7

77.2

60.3

64.3

48.5

63.60

63.60

Babita

21.9

29.8

22.1

23.9

23.6

24.26

24.26

Cuff
51

Attachment
Cuff

52

Topstitch

CALCULATIONS (CAPACITY, EFFICIENCY, AND PITCH TIME)

Operation

S.No

Operations

Average

Allowance

(sec)

(15%)

Operation
SAM

Capacity

Pitch

Upper

Lower

Efficiency

per hour

Time

Limit

Limit

0.42

0.47

0.37

Cuff
1

Hemming

18.12

2.72

0.35

0.54

173

Cuff Making

25.24

3.79

0.48

0.76

124

20.42

3.06

0.39

0.61

153

10.28

1.54

0.20

0.31

305

0.90

0.12

0.18

522

17.28

2.59

0.33

0.52

181

11.14

1.67

0.21

0.33

281

33.2

4.98

0.64

0.99

94

Collar
3

Profile
Collar
Margin

Cutting
Collar

Turning

Cuff turning
Placket Strip

joining
Collar Band

Marking
Cuff
Trimming

and Ironing

30.54

4.58

0.59

0.91

103

21.68

3.25

0.42

0.65

144

27.72

4.16

0.53

0.83

113

8.76

1.31

0.17

0.26

357

34.66

5.20

0.66

1.04

90

Collar
10

Ironing
Collar

11

Topstitch
Collar
Marking and

12

trimming
Collar Band

13

Attachment

Collar Peak
14

Making

15.44

2.32

0.30

0.46

203

10.82

1.62

0.21

0.32

289

27.04

4.06

0.52

0.81

116

18.52

2.78

0.35

0.55

169

21.82

3.27

0.42

0.65

143

55.39

8.31

1.06

1.66

57

24.76

3.71

0.47

0.74

126

19.76

2.96

0.38

0.59

158

27.9

4.19

0.53

0.84

112

24.76

3.71

0.47

0.74

126

12.36

1.85

0.24

0.37

253

46.23

6.93

0.89

1.38

68

27.4

4.11

0.53

0.82

114

12.19

1.83

0.23

0.37

257

Wash Care
Label
15

Attachment
Main label

16

Attachment
Back Pleat

17

Making
Front Dart,
Pocket

18

Marking
Placket

19

Attachment
Back Yoke

20

Topstitch
Back yoke

21

Attachment
Placket

22

Attachment
Placket

23

Topstitch
Placket
Temporary

24

Stitch
Placket
Temple

25

Making
Front Dart

26

Making
Pocket

27

Hemming

Pocket
28

Fusing

30.63

4.59

0.59

0.92

102

19.2

2.88

0.37

0.58

163

49.75

7.46

0.95

1.49

63

26.2

3.93

0.50

0.78

119

21.48

3.22

0.41

0.64

146

10.82

1.62

0.21

0.32

289

23.96

3.59

0.46

0.72

131

3.44

0.52

0.07

0.10

910

23.34

3.50

0.45

0.70

134

32.79

4.92

0.63

0.98

95

42.05

6.31

0.81

1.26

74

Pocket
29

Ironing
Pocket

30

Attachment
Shoulder

31

Attachment
Shoulder

32

Topstitch
Collar

33

Attachment
Back Neck
Temporary

34

Stitch
Sleeve
placket

35

Attachment
Cuff

36

matching
Sleeve
Temple

37

Making
Sleeve

38

Attachment
Armhole

39

Topstitch

57.56

8.63

1.10

1.72

54

40

Checking

22.94

3.44

0.44

0.69

136

71.24

10.69

1.37

2.13

44

21.26

3.19

0.41

0.64

147

Side Seam
41

Attachment
Sleeve Pleat

42

Making

Bottom
43

Hemming

24.36

3.65

0.47

0.73

129

41.9

6.29

0.80

1.25

75

63.6

9.54

1.22

1.90

49

24.26

3.64

0.46

0.73

129

Collar
44

Finishing
Cuff

45

Attachment
Cuff

46

Attachment

TOTAL SAM CALCULATED= 23.39 min

Pitch Diagram

Time

TIME STUDY AFTER IMPLEMENTATION OF OUR METHODS

Time Study

S.No.

Operations

Operator
Name

c1
(sec)

c2
(sec)

c3
(sec)

c4
(sec)

c5
(sec)

average
time
(sec)

Operation
Average
(sec)

Cuff
Hemming

Sadhna

16

18

20.7

19.4

16.5

18.12

18.12

Cuff Making

Meena

24.4

25.7

24.4

26.1

25.6

25.24

25.24

Collar Profile Sushma

22.2

24.2

21.1

16.5

18.1

20.42

20.42

Collar
Turning

Jayalaksh
mi

6.12

5.3

7.1

5.5

6.00

6.00

Cuff Turning

Hemlata

17.4

16

16.9

18.7

17.4

17.28

17.28

Front
Placket Strip
joining

jyoti

11.7

10.6

11.9

9.8

11.7

11.14

11.14

Tara

31.5

30.5

38

33.6

32.4

33.20

33.20

Anita

29.5

34.1

33.3

27.4

28.4

30.54

30.54

Raju

20.3

18.9

25

20.4

23.8

21.68

21.68

Kusum

29.3

27.6

27.6

25.6

28.5

27.72

27.72

Laxmi

9.4

6.2

9.5

11.7

8.76

8.76

11

Collar Band
marking
Cuff
trimming
and ironing
Collar
ironing
Collar
Topstitch
Collar
Marking and
trimming

12

Collar band
attachment

Poonam

41.7

35.4

32.6

33.6

30

34.66

34.66

13

Collar Peak
Making

Renu

15.3

15.4

16.3

15.1

15.1

15.44

15.44

14

Wash care
and main
label
attachment

Brahmwati

29.7

30.6
7

29.2
2

29.8

30.5

29.98

30.40

15

Back pleat
making

Reena

22.9

18.9

18.4

15.9

16.5

18.52

18.52

16

Front dart,

Soni

23.4

23.5

21.1

19.1

22

21.82

21.82

8
9
10

pocket
marking
17
18

Front
Placket
attachment

Dinesh
Pushpende
r

59.4

49.8

68.9

39.2

47.8

53.02

35.5

30.4

28.5

47.6

46.8

37.76

45.39

19

Back yoke
Attachment

Mohini

22.2

24.1

27.1

25.4

23.8

24.52

24.76

20

Back Yoke
Topstitch

Halima

16.9

18.2

26.7

16.4

20.6

19.76

19.76

Jancy

25.5

33.5

28.4

26.7

25.4

27.90

27.90

Babli

11.3

16.1

12.2

11.3

11

12.38

12.38

Mukesh

51.4

64.1

42.6

59.5

48.4

53.20

Sunita

44.4

40.3

36.8

36.9

37.9

39.26

Anita

27.7
12.1
2

26.1

29.7

27.8

27.40

27.40

Parvati

25.7
11.0
1

11.6

13.3

12.19

12.19

Seema

28.4

30.9

29.1

12.9
34.3
5

30.4

30.63

30.63

Sunil

19.3

19.4

19

19.2

19.1

19.20

19.20

Anu

36.4

38.3

45.9

49.5

39.1

41.84

32.1

28.7

42.5

42.5

32.5

35.66

Vibha

26.2

23.2

26.8

30.2

24.6

26.20

26.20

Reeta

20

19.9

21.9

24.6

21

21.48

21.48

Ramvati

12.9

9.8

8.9

10.5

12

10.82

10.82

Gudiya

23.7

27.3

23.7

24.2

20.9

23.96

23.96

Ram kumar

1.72

1.73

1.71

1.72

1.73

1.72

1.72

Bhumi

21.4

23.3

24.7

26.1

21.2

23.34

23.34

31

Placket
Topstitch
Placket
Temporary
Stitch
Placket
temple
Making
Placket
temple
Making
Front dart
making
Pocket
hemming
Pocket
Fusing
Pocket
Ironing
Pocket
Attachment
Pocket
Attachment
Shoulder
attachment

32

Shoulder
Topstitch

21

22

23

24
25
26
27
28
29
30

35

Collar
attachment
Back neck
temporary
Stitch
Sleeve
placket
attachment

36

Cuff

33

34

46.23

38.75

matching

37

38
39
40
41
42
43
44
45
46
47
48
49
50

Sleeve
Temple
Making
Sleeve
Temple
Making
Sleeve
attachment
Sleeve
attachment
Armhole
Topstitch
Armhole
Topstitch
Checking
Side seam
Attachment
Side seam
Attachment
Sleeve pleat
making
Bottom
hemming
Collar
finishing
Cuff
attachment
Cuff
Topstitch

kumari

Anju

31.8

34.9

26.4

44.2

28

33.06

Mamta

29.4

34.7

29.1

31.2

38.2

32.52

Bala

49.3

32.6

34.4

31.7

35.4

36.68

Ashok

51.6

50.6

46.5

42.3

47.42

Poonam

59.6

37

42.8

46.1
17.4
4

26.6

36.69

Surender

49.8

60.2

50

50

62.2

54.44

Manju

21.9

22.2

27

19.4

24.2

22.94

Saroj

38.3

66.5

55.3

46.1

52.7

51.78

Pooja

70.2

61.8

59.1

63.3

69.1

64.70

Maya

20.4

24

21.5

21.2

19.2

21.26

21.26

Lalpari

40.2

40.3

56.2

41.9

45.36

24.36

Premlata

46.6

39.7

41.8

39.9

48.2
41.4
8

41.90

41.90

Urmila

57.7

67.2

50.3

54.3

38.5

53.60

53.60

Babita

21.9

29.8

22.1

23.9

23.6

24.26

24.26

32.79

42.05

45.56

22.94
58.24

Calculations (Sam,Capacity, Efficiency and Pitch time)

S.No

Operations

Operation
average
(sec)

Allowance
(15%)

Operation
SAM

Efficiency

Capacity
per hour

18.12

2.72

0.35

0.54

173

25.24

3.79

0.48

0.76

124

20.42

3.06

0.39

0.61

153

Cuff
Hemming
Cuff
Making
Collar
Profile

Collar
turning

0.90

0.12

0.18

522

Cuff
turning

17.28

2.59

0.33

0.52

181

11.14

1.67

0.21

0.33

281

33.2

4.98

0.64

0.99

94

30.54

4.58

0.59

0.91

103

21.68

3.25

0.42

0.65

144

27.72

4.16

0.53

0.83

113

1
2

12

Strip join
Joining
Collar
band
marking
Cuff
trimming
and ironing
Collar
ironing
Collar
Topstitch
Collar
marking
and
trimming

9
10
11

Pitch
Time

0.39
8.76

1.31

0.17

0.26

357

13

Collar
band
Attachment

34.66

5.20

0.66

1.04

90

14

Collar peak
Making

15.44

2.32

0.30

0.46

203

15

Wash care
and main
label
attachment

2.98

0.45

0.06

0.09

1050

17

Back pleat
making

18.52

2.78

0.35

0.55

169

Upper
Limit

Lower
Limit

0.44

0.34

21

Front dart,
pocket
marking
Placket
attachment
back yoke
Topstitch
Back yoke
attachment

22

Placket
Attachment

18
19
20

23

24

25
26
27
28
29
30
31
32
33

34

35
36

37

Placket
Topstitch
Placket
Temporary
Stitch
Placket
temple
Making
Front dart
making
Pocket
hemming
Pocket
fusing
Pocket
Ironing
Pocket
attachment
Shoulder
attachment
Shoulder
Topstitch
Collar
attachment
Back Neck
Temporary
Stitch
Sleeve
placket
attachment
Cuff
matching
Sleeve
temple
making

21.82

3.27

0.42

0.65

143

45.39

6.81

0.87

1.36

69

24.76

3.71

0.47

0.74

126

19.76

2.96

0.38

0.59

158

45.39

6.81

0.87

1.36

69

24.76

3.71

0.47

0.74

126

12.36

1.85

0.24

0.37

253

46.23

6.93

0.89

1.38

68

27.4

4.11

0.53

0.82

114

12.19

1.83

0.23

0.37

257

30.63

4.59

0.59

0.92

102

19.2

2.88

0.37

0.58

163

38.75

5.81

0.74

1.16

81

26.2

3.93

0.50

0.78

119

21.48

3.22

0.41

0.64

146

10.82

1.62

0.21

0.32

289

23.96

3.59

0.46

0.72

131

3.44

0.52

0.07

0.10

910

23.34

3.50

0.45

0.70

134

32.79

4.92

0.63

0.98

95

38
39
40
41

42
43
44
45
46

Armhole
attachment
Armhole
Topstitch
Checking
Side seam
Attachment
Sleeve
pleat
making
Bottom
hemming
Collar
finishing
Cuff
attachment
Cuff
Topstitch

42.05

6.31

0.81

1.26

74

45.56

6.83

0.87

1.36

69

22.94

3.44

0.44

0.69

136

58.24

8.74

1.12

1.74

54

21.26

3.19

0.41

0.64

147

24.36

3.65

0.47

0.73

129

41.9

6.29

0.80

1.25

75

53.6

8.04

1.03

1.61

58

24.26

3.64

0.46

0.73

129

TOTAL SAM Obtained

21.78

Pitch Diagram

RESULTS:
1. 5 bottleneck operations have been improved by adding containers and following
proper bundle system.

a. PLACKET ATTACH AND FINISH:

SAM of the operation before improvement: 1.06 min

SAM of the operation after implementation: 0.63 min

b. POCKET ATTACH

SAM of the operation before improvement: 0.95 min

SAM of the operation after implementation: 0.74 min

c. SIDE SEAM ATTACHMENT

SAM of the operation before improvement: 1.37 min

SAM of the operation after implementation: 1.12 min

d. ARMHOLE TOP STITCH

SAM of the operation before improvement: 1.10 min

SAM of the operation after implementation: 0.87 min

e. CUFF ATTACH

SAM of the operation before improvement: 1.22 min

SAM of the operation after implementation: 1.03 min

2. Clubbing of 2 operations: Main label Attach and Wash Care label

attach.

Wash Care Label

Attach
cycle 1

18.2

cycle 2

17.14

cycle 3

17.92

cycle 4

16.5

cycle 5

19.2

average
cycle time

17.79

Let the number of labels to be attached be 750.

Therefore, the time taken in attaching these labels= (750*17.79) sec= 13342.5 sec=
222.375 min= 3.70 hours.

Main Label Attach

cycle 1

29.2

cycle 2

33.04

cycle 3

23.6

cycle 4

23.3

cycle 5

26.1

average
cycle time
(sec)

27.04

Time taken to attach 750 labels= (750*27.04) sec = 20280 sec= 338 min= 5.63 hours.
Total time taken by both the labels= 9.33 hours
Total time taken to attach both labels separately to one garment= 44.83 sec

In order to club these two operations we need to make back pleat first and attach back
yoke to it. And after that we can club these two operations where both Main label and
Wash Care label at one machine by the same operator.

operation mane: wash care label attach

+ main label attach (as predicted)
cycle time 1

30.04

cycle time 2

31. 67

cycle time 1

29.22

cycle time 4

29.1

cycle time 5

31.6

Average cycle time (sec)

29.99

Time taken to attach labels to 750 pieces= (750*29.99) sec = 22492.5 sec = 374.875 min =
6.24 hours

Time saved per day= (9.33-6.24) hours = 3.09 hours

Time saved on one garment= (44.83-29.99) sec = 14.84 sec = 1.05% of SAM.

3. Margin cutting of collar band and collar should be eliminated.

collar/ collar
band trimming

collar band
attach

The two operations should be eliminated because either the marking or the initial cutting of
the collar band and collar should be done carefully. Moreover the collar assembly which is
done on SNLS Edge Cutter machine can also trims these edges. Therefore, these operations
could be clubbed and hence time can be the saved. The amount of time that could be saved
has been calculated as follows:
Let the number of pieces produced per day = 750

Time taken for collar band

trimming
cycle 1

9.57

cycle 2

8.1

cycle 3

8.38

cycle 4

7.57

cycle 5

8.12

average

8.34

Time taken to trim collar band for 750 pieces = (750*8.34) = 6255 sec = 104.25 min=
1.72 hours.

Similarly, for trimming 750 collar pieces in a separate edge cutter machine time taken =
750*7.58 seconds = 5685 seconds = 94.75 minutes = 1.57 hours.

time taken for collar

trimming
cycle 1

8.23

cycle 2

7.9

cycle 3

6.3

cycle 4

8.4

cycle 5

7.1

average

7.586

Therefore, by eliminating these two operations, a total of (1.72 + 1.57) hours could be
saved each day = 3.29 hours.
Also by eliminating these two operations 15.92 seconds can be reduced out of SAM of the
garment Style # 979B being manufactured for Target which = 1.13% of SAM.

4. After all the improvements:

We have managed to reduce :
SAM from 23.39 min to 21.59
Pitch Time from 0.42 min to 0.39 min