Productivity Improvement Project- Diagnostic Study Report 69 Few recommendations for sewing on reducing none value added operations Style: Long Sleeve Shirt Buyer: M & S Unite:1/C Line:02(Make Section) Collar Bottom Cut & Nose Shape Collar Bottom Cut & Nose Shape Process Name Existing Cycle Time In Min Man powe r Target Process Name Existing Cycle Time In Min Man power Target Collar band join Undefined 1 Collar band join Undefined 1 Collar band cut 0.22 1 272 Collar band cut & collar band shape 0.25 1 240 Collar band shape 0.23 1 260 Total 0.43 3 139 Total 0.25 2 240 Old Target 260 New Target 240 Saving Manpower 01 Saving Existing Cycle Time 0.18 Above proposed method is eliminating one non value-added operation from the process by removing the hand scissoring of the collar band. Removal of this non value added operation has no input to the quality of the product either. Existing Method Proposed Method One helpers is collar nose shape cut & other one turn collar band One helper collar nose shape cut & turn
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Productivity Improvement Project- Diagnostic Study Report
69
Few recommendations for sewing on reducing none value added
operations
Style: Long Sleeve Shirt Buyer: M & S
Unite:1/C Line:02(Make Section)
Collar Bottom Cut & Nose Shape Collar Bottom Cut & Nose Shape
Process Name Existing
Cycle Time
In Min
Man
powe
r
Target Process
Name
Existing
Cycle Time
In Min
Man
power
Target
Collar band
join
Undefined 1 Collar band
join
Undefined 1
Collar band cut 0.22 1 272 Collar band
cut &
collar band
shape
0.25
1
240 Collar band
shape
0.23 1 260
Total 0.43 3 139 Total 0.25 2 240
Old Target 260 New Target 240
Saving Manpower 01 Saving Existing Cycle Time 0.18
Above proposed method is eliminating one non value-added operation from the process by
removing the hand scissoring of the collar band. Removal of this non value added operation
has no input to the quality of the product either.
Existing Method Proposed Method
One helpers is collar nose shape cut & other
one turn collar band One helper collar nose shape cut & turn
Productivity Improvement Project- Diagnostic Study Report
70
Style: Buyer:
Unite:1/B Line:02
Front Pkt Folding by Two(2) Ironmen Front Pkt Folding by One(1) Ironman
Process Name Existing
Cycle Time
In Min
Man
powe
r
Target Process
Name
Existing
Cycle Time
In Min
Man
power
Target
Pkt hem
folding
0.32 1 187
Pkt folding
0.53
1
113
Pkt folding 0.58 1 103
Total 0.90 2 66 Total 0.53 1 113
Old Target 103 New Target 113
Saving Manpower 01 Saving Existing Cycle Time 0.37
Production is using two ironing operators to fold / press pocket hem and fold /press pocket.
This is a waste of capacity as one operator has the capacity to do both at a time. Proposed
method is to do both operations by one ironing operator. This method can be applied to all the
lines where the pocket ironing is required.
Existing Method Proposed Method
One ironman pocket hem ruling & other
pocket ruling
One ironman using for pocket folding
Productivity Improvement Project- Diagnostic Study Report
71
Style: Long Sleeve Shirt Buyer: GEORGE
Unite:2/B Line:02
Front Pkt Folding with False Stitch Front Pkt Folding without False Stitch
Process Name Existing
Cycle Time
In Min
Man
power
Target Process
Name
Existing
Cycle Time
In Min
Man
power
Target
Pkt false stitch 0.33 1 180
Pkt folding
0.85
1
71 Pkt iron 0.60 1 100
Total 0.93 2 66 Total 0.58 1 71
Old Target 100 New Target 71
Saving Manpower 01 Saving Existing Cycle Time 0.37
Production is using two machine operator to set a run stich on the pocket to make it easy for
ironing / pressing and use total of two ironing operators for the pocket press and two machine
operators for attaching the pocket. With the introduction of new method, it has been possible to
remove the run stich operators (2) and get the same line target required with ironing without
run stich.
Existing Method Proposed Method
Pocket false stitch & folding by using two
manpower.
Pocket folding by using one iron man
Productivity Improvement Project- Diagnostic Study Report
72
Inside Collar end after collar make using two manual cut marks while it has already
been cut by the overlook machine to make the smooth shape of collar. Without cut mark and
with cut mark process has been evaluated and as there is no effect to the quality, the helper
who put the cut mark was removed.
Style:5818 Buyer: M & S
Unite:1/C Line:(Male Section)
Before collar topstitch inside selvage cut by using