Project Work presentation

WELCOME TO MY PROJECT WORK PRESENTATION

PRESENTED BY:MD. SHAIF UDDIN

DEPARTMENT OF LEATHER PRODUCTS ENGINEERING

EXAM ROLL: 118REGISTRATION NO:3466

ILET,DU

TITLE OF MY PROJECT WORK

STUDIES ON THE IMPROVEMENT OF

PRODUCTIVITY THROUGH REDUCTION OF WORK CONTENT IN CLOSING

DEPARTMENT

AIMS OF THE PROJECT•Reducing work content.•Productivity Improvement.• Better utilization of manpower, material, plant and equipment.•Improved working method.•Reducing ineffective time.•Increasing efficiency.

Design of the product

Front View

Back View

1. Cutting all leather, lining & reinforcement materials

2. Splitting

3. Skiving

4. Inspection & Numbering

5. Marking

6. Edge coloring & Buffing

7. Zipper Cutting

8. Stamping/ Embossing

9. Gluing on leather, PVC, Rabose & EVA attaching on leather

10. Two pieces of front & back part leather stitching face to face with single and double needle flat bed

sewing machine & hammering and threads trimming.

Flow Diagram of Sequential

Operations

11. Foam attaching to front & back part leather by applying adhesive

12. Folding top edge of front part

13. Folding the top edge of back part keeping two sides raw edge

14. Attaching #5 no. metal zipper with runner on top edge of back part by applying adhesive

15. Attaching one edge of back zipper pocket lining on lower edge of zipper with folded top

edge of back part by applying adhesive

16. Stitching top edge of back part with zipper and one edge of back zipper pocket lining & thread

trimming

17. Folding two sides of back top Patti & hammering

18. Attaching back top Patti with zipper and raw edge of back part by applying adhesive

19. Attaching another edge of back zipper pocket lining on top edge of zipper with folded back top

Patti by applying adhesive

20. Stitching back top Patti with zipper , raw edge of back part and another edge of zipper pocket

lining & thread trimming

21. Stitching two opened edge of back zipper pocket lining & thread trimming

22. Attaching EVA with two gusset

23. Folding top edge of two gusset & hammering

24. Gluing on two parts of ring loop and attaching with hammering

25. Stitching ring loop with square ring at marking position on gusset & threads trimming

26. Belt folding 6mm from edge with glue

27. Attaching both part of belt & hammering

28. Belt stitching 2.5 mm from edge & threads trimming

29. Attaching rabose with bottom

30. Folding two edge of bottom & hammering

31. Attaching two gusset with bottom by applying adhesive

32. Stitching two gusset with bottom & thread trimming

33. Stitching front & back part with stitched gusset and bottom part & thread trimming

34. Square ring, belt loop & buckle fitting with belt

35. Stitching belt with gusset of bag & threads trimming

36. Attaching foam with flap upper by applying adhesive

37. Attaching PVC on the attached foam of flap upper by applying adhesive

38. Folding the round of flap upper & hammering

39. Attaching EVA sheet with two counter flap side strap

40. Folding two counter flap side strap & hammering

41. Attaching two counter flap side strap with counter flap by applying adhesive

42. Stitching two counter flap side strap with counter flap & thread trimming

43. Attaching EVA with counter flap bottom strap

44. Folding counter flap bottom strap & hammering

45. Attaching counter flap bottom strap with counter flap by applying adhesive

46. Stitching counter flap bottom strap with counter flap & thread trimming

47. Attaching flap upper & counter flap by applying adhesive

48. Stitching flap upper & counter flap with double needle sewing machine & thread trimming

49. Fixing top part of magnet on the flap

50. Stitching flap with back top Patti by double needle sewing machine & thread trimming

51. Fixing bottom part of magnet on front part of bag

52. Preparation of Handy pocket

53. Stitching Handy pocket with front part inner lining & threads trimming

60. Double face adhesive tape applying on the edge of inner lining & folding

59. Stitching two inner gusset lining with front and back part inner lining & threads trimming

58. Stitching two sides of inner zipper pocket lining & threads trimming

57. Stitching inner zipper pocket lining with 3 No. nylon zipper & threads trimming

56. Attaching inner zipper pocket lining with 3 No. nylon zipper

55. Attaching #3 no. nylon zipper with runner & puller at folded zipper portion of back part inner

lining

54. Folding four edges of zipper cut portion of back part inner lining

64. Puller edge stitching 2.5mm around & threads trimming

63. Puller edge folding with glue

62. Inner lining stitching with body 2.5mm top edge & threads trimming

61. Edge of folded inner lining attached with the edge of bag body

65. Puller setting with zipper runner by fitting o-ring of metal zipper

66. Final stitch inspection

67. Cleaning and dressing

68. Stuffing

69. Inserting Bur code, Internet level, Price tag & safety label

70. Final checking and finishing

71. Packing of Bag

Work content Work content means the amount of work "Contained in" a given product or process measured in man-hour or machine hour. The basic work content is the time the product would take to manufacture on the operation to perform, if the design or specification was perfect, if the process of method of manufacture or operation was perfectly carried out, and if there was no loss of working time from any cause whatever during the period of the operation.

The basic work content is the irreducible minimum time theoretically required to produce one unit of output.

Total Work Content = Basic Work Content + Added Work Content

PRODUCTIVITY A general definition of productivity is the relationship between the output generated by production and the input provided to create this output.

Out putProductivity = ----------------- In put

From the definition of productivity, it is apparent that a higher total productivity may result, if-

• More output is produced with the same on lesser input.• The Same output is produced with lesser input, and• More output is produced with more input; the proportional increase in output being more that the increase in input.

PRODUCTIVITY IMPROVEMENT TECHNIQUES

I. Technology basedII. Employee basedIII. Product basedIV. Task basedV. Material based

WORK STUDY

WORK MEASUREMENTWork Measurement is the application of techniques designed to establish the time for a qualified worker to carry out a specific job at a defined Level of performance.

Work Measurement techniqueTime study.Synthesis.Predetermined Motion Time System (PMTS).Analytical Estimate.Work Sampling.

TIME STUDYThe time study is a work measurement technique for

recording times and rates of working for the elements of a specified job carried out under specified conditions, and for analyzing the data so as to obtain the time necessary for

carrying out job at a defined level of performance

Basic Time Study Equipment StopwatchA study boardTime study formSmall calculatorMeasuring instruments such as a measuring tape, steel rule, spring balance etc.

Critical Examination: (Basic Analysis)Every activity should be subjected to the following question asked one after the other in their proper sequence. The answers of these questions wilt from the basis for the development of the improved method: 1.Purpose?2. Place?3. Sequence?4.Person?5.Method?

Cutting all leather, lining & reinforcement materialsSplitting

SkivingInspection & Numbering

MarkingEdge coloring & Buffing

Zipper CuttingStamping/ Embossing

Gluing on leather, PVC, Rabose & EVA attaching on leatherTwo pieces of front & back part leather stitching face to face with single and double needle flat bed sewing machine & hammering and threads trimming.

Foam attaching to front & back part leather by applying adhesive Folding top edge of front part

Folding the top edge of back part keeping two sides raw edgeAttaching #5 no. metal zipper with runner on top edge of back part by applying adhesive

Attaching one edge of back zipper pocket lining on lower edge of zipper with folded top edge of back part by applying adhesiveStitching top edge of back part with zipper and one edge of back zipper pocket lining & thread trimming

Folding two sides of back top Patti & hammeringAttaching back top Patti with zipper and raw edge of back part by applying adhesive

Attaching another edge of back zipper pocket lining on top edge of zipper with folded back top Patti by applying adhesiveStitching back top Patti with zipper , raw edge of back part and another edge of zipper pocket lining & thread trimming

Stitching two opened edge of back zipper pocket lining & thread trimmingAttaching EVA with two gusset

Folding top edge of two gusset & hammeringGluing on two parts of ring loop and attaching with hammering

Stitching ring loop with square ring at marking position on gusset & threads trimmingBelt folding 6mm from edge with glue

Attaching both part of belt & hammeringBelt stitching 2.5 mm from edge & threads trimming

Attaching rabose with bottom Folding two edge of bottom & hammering

Attaching two gusset with bottom by applying adhesiveStitching two gusset with bottom & thread trimming

Stitching front & back part with stitched gusset and bottom part & thread trimmingSquare ring, belt loop & buckle fitting with belt

Stitching belt with gusset of bag & threads trimmingAttaching foam with flap upper by applying adhesive

Attaching PVC on the attached foam of flap upper by applying adhesiveFolding the round of flap upper & hammering

Attaching EVA sheet with two counter flap side strap Folding two counter flap side strap & hammering

Attaching two counter flap side strap with counter flap by applying adhesiveStitching two counter flap side strap with counter flap & thread trimming

Attaching EVA with counter flap bottom strap Folding counter flap bottom strap & hammering

Attaching counter flap bottom strap with counter flap by applying adhesiveStitching counter flap bottom strap with counter flap & thread trimming

Attaching flap upper & counter flap by applying adhesiveStitching flap upper & counter flap with double needle sewing machine & thread trimming

Fixing top part of magnet on the flapStitching flap with back top Patti by double needle sewing machine & thread trimming

Fixing bottom part of magnet on front part of bagPreparation of Handy pocket

Stitching Handy pocket with front part inner lining & threads trimmingFolding four edges of zipper cut portion of back part inner lining

Attaching #3 no. nylon zipper with runner & puller at folded zipper portion of back part inner liningAttaching inner zipper pocket lining with 3 No. nylon zipper

Stitching inner zipper pocket lining with 3 No. nylon zipper & threads trimmingStitching two sides of inner zipper pocket lining & threads trimming

Stitching two inner gusset lining with front and back part inner lining & threads trimmingDouble face adhesive tape applying on the edge of inner lining & folding

Edge of folded inner lining attached with the edge of bag bodyInner lining stitching with body 2.5mm top edge & threads trimming

Puller edge folding with gluePuller edge stitching 2.5mm around & threads trimming

Puller setting with zipper runner by fitting o-ring of metal zipperFinal stitch inspectionCleaning and dressing

StuffingInserting Bur code, Internet level, Price tag & safety label

Final checking and finishingPacking of Bag

0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000

Cutting all leather, lining & reinforcement materials

Skiving

Marking

Zipper Cutting & Stamping/ Embossing

Two pieces of front & back part leather stitching face to face with single and double needle flat bed sewing machine & hammering and threads trimming.

Folding top edge of front part & Folding the top edge of back part keeping two sides raw edge

Attaching one edge of back zipper pocket lining on lower edge of zipper with folded top edge of back part by applying adhesive

Folding two sides of back top Patti & hammering

Attaching another edge of back zipper pocket lining on top edge of zipper with folded back top Patti by applying adhesive

Attaching EVA with two gusset & Folding top edge of two gusset & hammering

Stitching ring loop with square ring at marking position on gusset & threads trimming

Attaching both part of belt & hammering

Attaching rabose with bottom

Attaching two gusset with bottom by applying adhesive

Stitching front & back part with stitched gusset and bottom part & thread trimming

Stitching belt with gusset of bag & threads trimming

Attaching PVC on the attached foam of flap upper by applying adhesive

Attaching EVA sheet with two counter flap side strap

Attaching two counter flap side strap with counter flap by applying adhesive

Attaching EVA with counter flap bottom strap

Attaching counter flap bottom strap with counter flap by applying adhesive

Attaching flap upper & counter flap by applying adhesive

Fixing top part of magnet on the flap & Fixing bottom part of magnet on front part of bag

Preparation of Handy pocket

Folding four edges of zipper cut portion of back part inner lining and Attaching #3 no. nylon zipper with runner & puller at folded zipper portion of back part inner lining

Stitching inner zipper pocket lining with 3 No. nylon zipper & threads trimming

Stitching two inner gusset lining with front and back part inner lining & threads trimming

Edge of folded inner lining attached with the edge of bag body

Puller edge folding with glue

Puller setting with zipper runner by fitting o-ring of metal zipper

Cleaning and dressing

Inserting Bur code, Internet level, Price tag & safety label

Packing of Bag

0 200 400 600 800 1000 1200 1400 1600 1800 2000

RESULT OF THE PROJECT According to table-1

The existing production of the closing line-1 was 250 pieces Bag per day.Standard output of the line-1 (at 100% capacity) was 509 pieces per day.Total no of worker was 80.Work content (Minutes) per bag was 75.45So the efficiency of the existing line was 49.12%

According to table -2 & table -3

Standard output of the modified closing line -1 (at 100% capacity) could be 561Pieces Bag per day.Work content (Minutes) of proposed line is 68.37 minutes.So productivity increasing 10.21% by using same labour.Work content reduction is 7.08 minutes.  

SUGGESTION AND RECOMMENDATION

1. Line layout should be balanced according to sequence of operation.

2. Show board may be made for every article to ensure correct specification

3. Less order may be avoided.4. Supervisor and worker need training.5. Attitude towards work should be positive.6. A preventive maintenance schedule should be strictly followed.7. Incentives may be introduced to skill enhancement.8. The sewing operator may be trained to keep hand away from balance wheel.9. Skilled operators must be appointed for critical operations.10. Line balancing and workers distribution may be done using standard times.11. A regular training program (Non-Technical and Technical) on transactional analysis,

Motivation, quality concept, productivity etc. could be organized.12. Workers should be encouraged to point out any inconstancies.13. Efficiency calculation should be done on monthly basis.14. Workers rating could be introduced according to the performance so that it acts as a

guide for improvement.15. The wage difference of machine operator and manual operator is very less; therefore

there is little motivation for skill enhancement. Wages difference should be more.16. After critical operation, there should be stage inspection.17. During production, rework may not be done which need to change thread. 

THANKS TO ALL