1. Welcome

2. Title of the Thesis
Productivity Improvement of a Sewing Line in a Selected Company of Ready Made Garment Industry by Using Assembly Line Balancing Technique
Presented By
Md. Anwar Hossen
Reg. No
Md. Shakil Khan
Reg. No

3. Introduction Now the business world is very dynamic and competitive.
This competitive situation can only be managed by applying operations management tools.
As example, for repetitive production system Assembly Line Balancing is very effective tool.
Line balancing can ensure the improvement of:
efficiency
production rate
productivity and
Reduction of:
idle time
resource utilization
production cost etc.

4. Objectives
To evaluate the existing assembly line for finding the current status
To reduce idle time, if any
To improve productivity, if possible

5. Research Methodology The steps involved in case study are:
[page 13]
The steps involved in case study are:
Step 1: Determining the research questions
Step 2: Selecting the cases and analysis techniques
Step 3: Prepare to collect the data
Step 4: Collect data in the field
Step 5: Evaluate and analyze the data
Step 6: Prepare the report

6. Case Company On the assembly process of Short Pant
In a manufacturing industry named “Mondol Fabrics Ltd.”, Nayapara, Kashimpur, Gazipur

7. Tools & Techniques Evaluation parameters of existing assembly process:
efficiency
idle time
production time
production rate
production cost &
productivity
Scientific technique “Six-Step Assembly Line Balancing”
Improvement analysis “Sequential Improvement Technique”

8. Evaluation

9. Six-Step Assembly Line Balancing
[page 7]
It has the following six steps:
Step 1. Select task, estimate time & draw precedence diagram
Step 2. Specify the daily output level & calculate cycle time
Step 3. Calculate the minimum number of work centers
Step 4. Develop an initial layout
Step 5. Evaluate the current layout
Step 6. If possible, improve the layout

10. Time Study
[page 3]
Time study is the combination of a series of activities as follows:
Step 1: Define the Task
Step 2: Breaking the Job into Elements
Step 3: Estimate the Required Number of Observation
Step 4: Record the Times and Ratings of Performance
Step 5: Average Observed Time
Step 6: Normal Time
Step 7: Allowance
Step 8: Standard Time

11. Collected Data
[page 19] :

12. Precedence Diagram
[page 21]

13. Initial Process Control Chart

14. Evaluation Results Items Designed Results Actual Results Cycle Time
[page 24]
Items
Designed Results
Actual Results
Cycle Time
1.08 Min.
0.588 Min.
Idle Time
71.74 %
48.09 %
Efficiency
28.26 %
51.91 %
Production Rate
55 Piece/Hr.
102 Piece/Hr.
No. of Work Station 61
Total Process Time
Min.
Production Cost
90.70 TK/Piece
Selling Price
99.96 TK/Piece
Productivity
1.102

15. Improvement

16. Reasons for Improvement
Efficiency % bellow the standard
Productivity close to minimum level
Existing line is unbalanced

17. Sequential Improvement Technique
[page 9]
It has three sequential steps:
Step 1: Withdrawal of Idle Resources
Step 2: Redistribution of Tasks
Step 3: Bottleneck Reduction
a. By Existing Resources &
b. By Additional Resources

18. Summary after Withdrawal of Idle Resources
[page 28]
Items
Before Improvement
After Improvement
Cycle Time
1.08 Min.
Idle Time
71.74 %
70.86 %
Efficiency
28.26 %
29.14 %
Production Rate
55 Piece/Hr.
No. of Work Station 61
Total Process Time
Min.
Min.
No. of M/C & Operator 46 41
No. of Helper 34 33

19. Summary after Redistribution of Tasks
[page 34]
Items
Before Improvement
After Improvement
Cycle Time
1.08 Min.
Idle Time
71.74 %
64.22 %
Efficiency
28.26 %
35.78 %
Production Rate
55 Piece/Hr.
No. of Work Station 61 50
Total Process Time
Min.
Min.
No. of M/C & Operator 46 41
No. of Helper 34 22

20. Manufacturing Cost after Improvement
[page 41]
With existing Resources:

21. Comparative Summary after Improvement
[page 41]
With Existing Resources:

22. Manufacturing Cost after Improvement
[page 42]
With Additional Resources:

23. Comparative Summary after Improvement
[page 42]
With Additional Resources:

24. Improvement in Terms of Money
[page 43]
By using Sequential Improvement Technique:
Profit gain = TK
Time saving = ( ) days
= 5.1 days
By this time the industry can also gain,
= (4576 piece/day)*(15.05 TK/piece)*(5.1 days)
= TK
So,
Total additional profit gain by improvement,
= ( ) TK
= TK

25. Achievement of Objectives

26. Idle Time Reduction at Different Stages of Improvement

27. Productivity Gain at Different Stages of Improvement

28. Analytical Results Considering Different Allowance

29. Productivity Gain for Different Allowance

30. Efficiency Gain for Different Allowance

31. Errors/Mistakes in Our Report

32. Major Mistakes
In page 1: A world dominating business sector can fall down suddenly. (organization)
In page 4: Average observed valve. (value)
In page 15: After Introduction we have used STEP: ONE. (before STEP: ONE will be 4.2 Six-Step Assembly Line Balancing & after STEP: ONE will be Time Study)
In page 25 & 28: The given control charts are wrong.
In page 34: We have used 39.3 % allowance. (20 %).
In page 37: Typing mistake for value of SSV & SMV.

33. Limitations of this Thesis

34. Limitations Assumption about the current method.
Omission of performance rating.
Omission of cross study for different product.
Lack of our experience.

35. Thank You

36. Questions ???