SEWING RESEARCH INSTITUTE
JUKI Machinery Bangladesh Ltd.
Presentation for New age Garments Ltd.
Saidur RahmanPlant Engineer,JUKI
Saad Bin A.RashidPlant Engineer,JUKI
Presented by:
SEWING RESEARCH INSTITUTE
©2010 JUKI Corporation
A B C D E
A B C D E
A B C D E
A B C D E
A B C D E
No.1
No.2
No.3
No.4
No.5
Exercise-1
SEWING RESEARCH INSTITUTE
©2010 JUKI Corporation
Result
Balance Layout OutputWork inProcess
1 × ○ 14 25
2
3
SEWING RESEARCH INSTITUTE
©2010 JUKI Corporation
A B C D E
A B C D E
A B C D E
A B C D E
A B C D E
No.1
No.1
No.5
No.2
No.3
No.3
No.4
No.4
No.2
No.5
Exercise-2
SEWING RESEARCH INSTITUTE
©2010 JUKI Corporation
Result
Balance Layout OutputWork inProcess
1 × ○ 14 25
2 ○ × 18 8
3
SEWING RESEARCH INSTITUTE
©2010 JUKI Corporation
Exercise-3
A B C D E
A B C D E
A B C D E
A B C D E
A B C D E
No.1
No.2
No.3
No.4
No.5
SEWING RESEARCH INSTITUTE
©2010 JUKI Corporation
Result
Balance Layout OutputWork inProcess
1 × ○ 14 25
2 ○ × 18 8
3 ○ ○ 25 6
SEWING RESEARCH INSTITUTE
©2010 JUKI Corporation
Line Balance
Operator1
Operator2
Operator3
Operator4
Operator5
5letters
2 letters
8 letters
3 letters
7 letters
5 letters
100% Efficiency!
SEWING RESEARCH INSTITUTE
©2010 JUKI Corporation
What is productivity?
Target daily capacity =
Daily work hours ×Number of workers
Net total ×Processing time
(1+Allowance rate)
× Organization efficiency
SEWING RESEARCH INSTITUTE
CONDITION OF SEWING LINE Existing 85% Effeciency
Daily work time (in sec) 36000 Sec (10 Hours)
Number of workers70 (26 Helpers, 44
Operators) (37.14% Helper)
Allowance rate 24.7%
Net total processing time (sec) 1445 sec (24 min 6 Sec)
Daily production Pcs (8 Hours)861 Pcs,
(Per Hour 87 Pcs)1172 pcs(per hour
118 pcs)
Day wise productivity (pcs/worker) pc / worker
Line Condition
SEWING RESEARCH INSTITUTE
©2014 JUKI Corporation
Existing Layout
A01
A02
B03
B04
A08
C02
C05
C03
C09
D01
E08
A04
QC
A06
B02
A08
C06
E0 4
E06
A03
A05
A07
B01
C01
C07
E01
E05
C04B05
QC
C08
C10
D02,D03
E02
E02
E03
E07
E09
E08E09
QC
E10
E12
E12
E13
E13
E14
E15
E15
E16
E18
E18
E19
E19
E20
E21
E22
E2 3
E26
E27
E27
E24
E25
F01Iron
E20
E11
G03
E17
SEWING RESEARCH INSTITUTE
©2010 JUKI Corporation
A01
A02
B03
A08
C02
C05
C03
C09
D01
E08
A04
QC
A06
B02
A08
E01
E04
E06
A03
A05
B01
C01 C04
QC
C10
D02,D03
E07
E09
E08E09
QC
E10
E12
E12
E13
E13
E14
E15
E15
E1 6
E18
E18
E19
E19
F02
E21
E22
E23
E26
E27
E27
E25
E20
E17
A07
B04
B05
C06
C0 7
C08
G01
G02
G03
E02
E03 E05
E02
E11
E20
F01
Improved Layout
SEWING RESEARCH INSTITUTEHow many stitching hours/day?
10 hours
1.5hoursStitching
5.5hoursPick up & dispose
3hoursWastage!!!
Increase stitching time = increase output
Your Factory Allowance 24.7%
©2013 JUKI Machinery Bangladesh Ltd.
SEWING RESEARCH INSTITUTE
©2010 JUKI Corporation
Allowance : 24.7%
©2011JUKI Corporation
0.0 %
0.5 %
1.0 %
1.5 %
2.0 %
2.5 %
3.0 %
3.5 %
4.0 %
4.5 %
Your factory Japan Average *Average of investigation of 333 factory by JUKI
0.0 %
10.0 %
20.0 %
30.0 %
40.0 %
50.0 %
60.0 %
70.0 %
SEWING RESEARCH INSTITUTE
©2010 JUKI Corporation
Line Balance 62.4%
©2011 JUKI Corporation
05
10
15
20
25
30
35
Pro
ce
ss T
ime
(s
ec
.)
Process Name (Operator No.)
24.23
16.97
20.6
SEWING RESEARCH INSTITUTE
©2010 JUKI Corporation
Reduce Bottle Neck
Attach Back Yoke Sew shoulder
Work can be shared to reduce bottleneck
SEWING RESEARCH INSTITUTE
©2010 JUKI Corporation
Topstitch sleeve
Existing( 39 sec+37 sec)= 76 sec
Improved (42 sec)
SEWING RESEARCH INSTITUTE
©2010 JUKI Corporation
Attach sleeve
Existing( 28 sec+24 sec)= 52 secImproved (37 sec)
SEWING RESEARCH INSTITUTE
CONDITION OF SEWING LINE Existing Kaizen line
Daily work time (in sec) 36000 Sec (10 Hours)36000 Sec (10
Hours)
Number of workers70 (26 Helpers, 44
Operators) (37.14% Helper)66 (22 Helpers, 44 Operators)
Allowance rate 24.7%24.7%
Net total processing time (sec) 1445 sec (24 min 6 Sec)1431 sec (23 min
40 Sec)
Daily production Pcs (8 Hours)861 Pcs,
(Per Hour 87 Pcs)995 pcs
(per hour 99 pcs)
Day wise productivity (pcs/worker) 12 pc / worker 15 pc / worker
Kaizen Line Condition
SEWING RESEARCH INSTITUTESummary (At a glance)
Process Process Before Reduce(Proposed)
Mark Front Part Mid Point(A08)
Mark Placket Join Position(A09)
1+1 0
Mark Button position(E24)
2 2
Attach loop(C03) Mark Centering position(C04)
1+1 1
Total: 3 Helper Can possible to Reduce
SEWING RESEARCH INSTITUTE
©2010 JUKI Corporation
05
10
15
20
25
30
35
Pro
ce
ss T
ime
(s
ec
.)
Process Name (Operator No.)
Kaizen Line Balance 74.6%
SEWING RESEARCH INSTITUTE
©2010 JUKI Corporation
Visual management
E08
QC
E10
E12
E1 2
E13
E13
E14
E15
E15
E1 6
E18
E18
E19
E19
E20
E21
E22
E23
E26
E2 7
E27
F01Iron
E20
E11
G03
E17
SEWING RESEARCH INSTITUTE
©2010 JUKI Corporation
KAIZEN (=Improvement)
It is ok…Don’t take itso seriously
Hesitate!!
All we need todo it is to makeSmall improvementslittle by little
It is a tough job.I cannot do it.