Apparel Production Analysis System

1Saturday, April 8, 2023

Work Study

Operational activities can be grouped into following three types: Value-added activities are activities which transform the materials into the exact product that the customer requires.

Non value-added activities are activities which aren’t required for transforming the materials into the product that the customer wants.

Incidental activities (necessary non value added work) : are activities that don’t add value from the perspective of the customer but are necessary to produce the product unless the existing supply or production process is radically changed.

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Saturday, April 8, 2023 3

Material, Labor, shipping, Equipment, Import duties, Suppliers’ cost

$25

Advertising and R&D $15

Profit $7

Retailers’ overhead $30

Retailers’ profit $10

$80 - $90


Work Study is a common term for techniques used for the examination of human work and systematic investigation of all the factors which affect the efficiency of the process, in order to seek improvements. Work study investigates the work done in an organization and aims at finding the best and the most efficient way of utilizing the available resources (man, material, money and machinery) to achieve best possible quantity and quality work in minimum possible time. Work study which involves least possible time and causes least possible fatigue to the worker.



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Work study is mainly concern with human work


• To reduce unnecessary work or excessive work, reduce cost, increase profit and improve efficiency.

• Maximum uses of resources.• Reduced additional expenditures.• Time reduce.• Productivity Increases.• To find the best method.• Set the standard time.• Smooth production flow with minimum interruption.• Reduce the cost of the product.• Reduction in rejection and rework.

Importance of work Study


Work Study Man• Exposure and experience to the various production

systems.• A good knowledge of methods and systems of work study.• A strong believe of improvement of work methods through

work study.• Mentally suited to the work.• Sincere and honest.• Enthusiastic.• Sympathy for people.• Good appearance and self confident.• Smart in dealing with people.


HUMAN FACTOR IN THE APPLICATION OF WORK STUDY

The human factor plays a very important role in the successful conducting and implementation of work study in organizations. The management who is responsible for spelling out the objectives and planning of work, the supervisor who translate these plans into day to day operations and continuously monitor them, the worker who carries out the operations, and the work study man who conducts the study, all of them have to contribute positively if the study has to succeed. The objective is to look at the ways in which these different interacting groups can contribute.


It is first necessary to have an understanding of how the management and supervisor form two distinct groups in an organization. While the management's tasks are to put forward the objectives of the organization and planning of the different activities, the supervisor’s jobs are to translate these tasks into day to day operations and monitor the progress by ensuring that the workers perform the work as desired, and by making relevant tools available to them. The supervisor thus acts as the liaison between the management and the worker.


The role of management for successful application of work study can be summarized as follows:


a) The management should define the organizational objectives clearly. This is important, as without clarity, the workers or supervisors may set their own objectives, which may be in conflict with those of the management. Work study aims at identifying a better method of doing work, and this better method is defined with respect to the organizational objectives.


b) The management must try to plan in a way so as to minimize certain ineffective time. In case there is some ineffective time due to management, and it is identified as a part of a work study, management should be open to suggestion and criticism.


c) Finally, the management should consciously attempt to maintain good relationship with the workers and provide a good working environment for them. This helps building up a mutual trust which is useful for any study to succeed.


The supervisory role in work study applications are summarized here:


a) As the liaison between the management and the workers, the supervisor should clearly communicate to the workers, the organizational objectives as laid down by the management. On the other hand, he should be able to give a picture to the management about the practical problems of the shop floor, to enable the management to set realistic goals.


b) As a person who is much closer to the actual jobs than the management, he should be fully aware of different aspects of the work including its limitations. This should help him in identifying potential areas of improvement, and he could be of help in selecting the proper work for study.


c) As a person who is responsible for operationalizing the plans, the supervisor has to be associated with the study right from selection of the job to be studied, to its implementation. This necessitates that he is open to share his ideas.


Role of the worker:

As the person who is actually doing the job, the worker plays a crucial role in successful application of any study. His values and attitude, his behavior, as an individual and also in group should be taken into consideration for the purpose of the study. His role in the study is summarized below:


a) The worker should not neglect his work or waste time unnecessarily. He needs to be aware of the fact that the result of lowering of productivity will affect him in the long run.


b) The worker should take interest in the work and take the initiative with work related factors. Often, it is possible to select the job to be studied through the initiative taken by the worker. Individual, formal or informal groups or sometimes unions can be used as a platform to initiate a study.


Qualified worker:

A qualified worker is an average person who has the right knowledge or right skill of doing the specific task, the best effort, high motivation and other attributes to accomplish a job up to satisfactory level

of quality, quantity and safety.


Standard work content:

The standard work content of an order is the time which would be taken by the labor force, if they were all working at a standard rate all the time without any interruption.


The standard work content is the time taken to manufacture the product or to perform the operation if the design or specification of the product provided were perfect, if the process or method of operation were perfectly carried out, and if there were no loss of working time for any cause (working other than standard speed, mc break down etc.) whatsoever during the period of operation. The standard work content is the irreducible minimum time theoretically required to produce one unit of output in the present condition.


Work content means the amount of work contained in a given product or a process measured in “work hours” or “machine hours”. In garments it is calculated in minutes.

• A standard work hour is the labor of one person for one hour if he were working at a standard speed without interruption and scarifying standard speed.

• A machine hour is the running of a machine for one hour.


Standard work content depends on:

• Number and size of cut parts.• Number and nature of seams.• Decorative features.• Cloth and accessories selection.• Stitches per inch.• Hand work.• Quality standards. Standard work contents depend upon the market or

buyer requirements.


Excess work content:

Excess work content is the amount of time other than standard work content which practically some time needed to complete the product due to many reasons.Policy Excess: Frequency of style change.Managerial Excess: Spent time by the supervisors which are not theirs. When a garments is badly made, it has to be reworked.

• Labor turnover-balancing upsets and training.• Operator training efficiency.• Absenteeism-balancing upsets and quality problems.• Operator performance.


Poor design and frequent design changes:

The product may be designed in such a way that it may require a large number of non standard of parts causing a lengthy time of assembly. Excessive variety of products and lack of standardization of products or their parts may mean that work has to be produced in small batches, with time loss as the operator adjusts and shifts from one batch to next.


Waste of materials:

The component of a product may be so designed that an excessive amount of material has to be removed to bring them to final shape. This increases the work content of the job and waste materials as well. Operations requiring cutting in particular need, careful examination to see if the resulting waste can be reduced to a minimum or reused.


Incorrect quality standards:

Quality standards that are too high or too low can increase work content. In industries, insisting on sometimes unnecessarily tight tolerances require extra time and corresponding waste of materials. On the other hand setting tolerances too loose may results in a large number of rejects. Deciding on appropriate quality control is an important efficiency consideration.


Poor layout and poor utilization of space:

The space used for any operation represents an investment. Proper utilization of space is an important source of cost reduction, particularly when an enterprise is expanding and needs an increased working area. Furthermore, a proper layout reduces wasted movement, time and effort.





Inadequate Material Handling

Raw materials, parts and finished products are invariably being moved from one place to another throughout a production system. The use of most appropriate handling equipment for the purpose can save time and effort.



Frequent stoppages as production changes from one product to another:

The proper planning and control of production operation can ensure that one production batch or order follows immediately another so that idle time of machinery, equipment or labor is eliminated or minimized.


Ineffective method of work:

A sequence of operations may be well planned but each or some of them done in a cumbersome manner. By examining the way a certain operation is carried out and devising a better method, ineffective time can be reduced.


Poor planning of inventory:

In every operation, raw material is usually ordered and stocked ahead of time and at every stage of the operation an inventory of so called “materials in progress” or semi finished products and various parts are temporarily stocked waiting to be processed. These various inventories represent a tied up investment. A proper inventory control system when installed can minimize such an idle investment while ensuring that the operators do not run out of material needed.


Frequent breakdown of machines and equipments:

Poor maintenance results in machinery and equipment often out of action, and idle time ensues while waiting for repairs. Installing an offline preventive maintenance system and mounting maintenance campaigns would ensure the smooth functioning of machinery and equipment.


Absenteeism and lateness:

If management fails to produce a financially safe and satisfying work climate, worker could respond by absenteeism, lateness or deliberately working slowly.


Poor workmanship:

If workers are improperly trained, the resulting poor workmanship can mean that the job has to be done again. Losses may also occur because of wasted material, time, concentration beak which results in slow start.


Accidents and occupational hazards:

If management fails to provide a safe and healthy place to work, accidents and occupational illnesses can occur, with resulting effect on morale and increased absenteeism.



Standard work content

Poor design and frequent design changes

Waste of materials

Incorrect quality standards

Poor layout and poor utilization of space

Inadequate Material Handling

Frequent stoppages as production changes from one product to another

Ineffective method of work

Poor planning of inventory

Frequent breakdown of machines and equipment

Absenteeism and lateness

Poor workmanship

Accidents and occupational hazards

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Product development reduces work content due to poor design.

Proper material utilization reduces and utilizes waste.

Quality control ensures proper standards and inspection methods.

Better layout and process planning reduces unnecessary movements.


Material handling adapted to activity reduces work content due to poor method of handling.

Good production planning and control reduces ineffective time.

Method study of an activity reduces work content due to poor method of work.

Inventory control defines appropriate and most economical inventory level. Such as EOQ model.


Preventive maintenance ensures longer life and continuous run of machines and equipments.

Proper management, personnel policy, attractive salary structure and good incentive plan can create a satisfactory working environment.

Training can develop appropriate skills.

Better working conditions improves morale and reduces absenteeism.

Difficulty in implementing work study:

Work study always involves itself in thorough investigation of all processes and factors that imply productivity by close supervision. It often bears open shortcoming of a person or a certain department. For example it may point out that a number of operators have been sitting idle due to shortage of raw material or say due to the non availability of a folder urgently required for an operation or that an approved sample or a swatch card was not supplied in time or that a pattern was defective. Thus work study often points its finger to the people in the organization which in turn prompts animosity towards the department. So, personnel working in this department should be very tactful in doing their jobs and handling people.


Role of top management in implementing work study:

But it is resolve of the top management of the

organization and its continuous support, that can help implementing work study in an enterprise. Because with the introduction of work study, working method will go under lot of change, which many old fashioned executives may not like to accept as they are used to do things as they always been doing.


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Work Study

Work Measurement

Time StudyPredetermined

Motion and Time Study

Method Study

Saturday, April 8, 2023

Date post:	08-Nov-2014
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Apparel Production Analysis System

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