OBJECTIVE:

TO IMPLEMENT WORKSTUDY CHARTS TO OBTAIN MAXIMUM UTLIZATION OF THE

RESOURCES AND OPTIMIZE WORKPLACE BY CHAINGING THE PLANT LAYOUT AND
WORKSTATION USIG THE PROCESS CHART.

PLANT LAYOUT AND WORKSTATION DESIGN

CUTTING SECTION

CUTTING SECTION EXISTING LAYOUT

CUTTING SECTION PROPOSED LAYOUT

CALCULATION CUTTING SECTION

FORMULA USED =PRODUCTION O/P = TOTAL TABLE * PRODUCTION
NO. OF TABLES

EXISTING
4

PROPOSED
6

TOTAL TABLE LENGTH

22*2+10*1+17*1=71MTS

PRODUCTION O/P PER DAY

71*60=4260

20*4+17*1+10*1=107mt
s
107*60=6420

Increase in production=6420-4260/6420*100=33.64%
COMPARISION B/W EXISTING & PROPOSED CUTTING SECTION LAYOUT
EXISTING
Lesser space utilization
Operations not arranged in sequence
Bottlenecks occurs
Production is less
Too much of material movement and
handling

PROPOSED
Maximum space utlization
Operations are arranged in sequence
Bottlenecks avoided
Higher production is achieved
Minimized material handling

SEWING SECTION LAYOUT

SEWING SECTION LINE

FINISHING SECTION LAYOUT

FINISHING SECTION EXISTING LAYOUT

FINISHING SECTION PROPOSED LAYOUT

Workstation design

The work station design affects the production rate, efficiency and the
accuracy with which an operation can be performed. A work station not only
needs space for the workers and the machine, there are plenty of other items

which also need accommodation. Space requirements and a few more factors
governing a good work station design are described below
Space requirements
Consideration of the space required, for the movement of material handling
equipments.
Easy access to safety stops in case of emergency.
Easy access to machine for inspection, lubrication, maintenance and repair.
Convenience of making foundations and machine installations.
Aisle space between one machine and the next.
Appropriate ventilating, lighting and safety arrangements.

WORKSTATION AT SEWING BATCH-EXISTING

WORKSTATION AT SEWING BATCH-PROPOSED

COMPARISON OF EXISTING VS. PROPOSED

DESCRIPTION

EXISTING WORK STATION

Needle distance from

center table edge
Time required to
manufacture one garment
from one batch
Enter of performance card
Movement of the operator
towards the center table

63cm

PROPOSED WORK
STSTION
57 cm

20 mins

18 mins

Disturbing the operstor

Restricted bythe the
barrier to a limit

Without disturing barrier

does not exsisit

DESCRIPTION
No. of operations / BATCH
To manufacture 1 garment
Hourly production per
batch
Daily production per batch
Daily production from
sewing section Proposed
Existing

EXISTING
20 OPERATIONS
20 MINS
3*20=60 GARMENTS/Hr

PROPOSED
20 OPERATIONS
18 MINS
3.33*20=66

60*8=480GARMENTS/DAY
480*6=2884
GARMENTS/DAY

66*8=528 GARMENTS/DAY
528*6=3168GARMENTS/D
AY

%efficiency=3168-2884/3168*100=9%

IMPLEMENTING WORK STUDY CHARTS IN APPAREL MANUFACTURING

Objective : To record the movements of man, machine & materials in a layout, study
the distance covered, time involved, interaction between them, identify the area for
improvement, and suggest a better way to overcome these problems.
WORK STUDY- DEFINITION
Work study is a generic term for those techniques, particularly method study& work
measurement, which are used in the examination of human work in all its context, &
which lead systematically to all the factors which affect the efficiency & economy of
the situation being reviewed, in order to effect improvement.

OUT LINE PROCESS CHART: An out line process chart is a process chart giving an
over all picture by recording in sequence only the main operation and inspection.

FLOW PROCESS CHART -The flow process chart as a process chart setting out the
frequency of the flow of a product or procedure by recording all event under review
using the process chart symbols

Man type
Material type
Equipment type

MAN TYPE- FLOW PROCESS CHART

A flow process chart which records what the worker does

FLOW PROCESS CHART- MAN TYPE FEEDING HELPER IN SEWING SECTION

MATERIAL TYPE FLOW PROCESS CHART

A FLOW PROCESS CHART WHICH RECORDS THE MOVEMENT OF MATERIALS, I.E. THE
CHANGES THE MATERIAL UNDERGOES IN LOCATION

TWO- HANDED PROCESS CHART

The two-handed process chart is a process chart in which activities of a workers
hands(or limbs) are recorded in their relationship to the other.

MULTIPLE ACTIVITY CHART

Is useful recording tool for situations where the work involves interactions of different subjects.
One or more workers looking after different machines or a group of workers working on loading
materials at one point.

MAN-MACHINE CHART FOR PLACKET TRIM & JOINT OPERATION

Existing condition: The operations, placket trim and placket joint were carried on by 2 different
operators at different places for a single batch.
Proposed condition: A single operator to perform both the operations on two machines placed
front & back of the operator , providing with a rotating chair.

MAN- MACHINE CHART FOR PLACKET TRIM & JOINT OPERATION

CONCLUSION
WITH THE APPLICATION OF WORK STUDY CHARTS IN APPAREL MANUFACTURING,
THE EFFECTIVE UTILIZATION OF RESOURCES ( MAN, MATERIAL & MACHINES) CAN BE
ACHIEVED
THE COST INVOLVED IN USING THESE CHARTS ARE VERY MINIMUM AND A SOLUTION
CAN BE DERIVED IN A SHORT PERIOD OF TIME