Cutting – Work Measurement

ObjectiveDetermining the Standard time of Sub-

Processes in Cutting for better Monitoring & Tracking. Sub- Processes of Cutting include Laying, Cutting, Numbering & Fusing.

Measure the work content & set the standard time for each sub processes in Cutting.

Recording Efficiencies of the Sub Processes in Cutting to understand scope for improvement.

MethodologyTime Measurement of each Cutting Sub Process

through Observation & Time Study.Arriving at SMV for each Sub Process.

Cumulative of all Sub processes (except Numbering) to give the total cutting SMV.

Setting Target for Each Sub Process at the rate of 100 % efficiency.

Monitoring the Set Target.Recording and Updating the Efficiencies

achieved.

Cutting Processes Layering/Spreading Cutting Stickering/Numbering Fusing

Factors Involved in Spreading

OPERATIONSOPERATIONS FACTORSFACTORS

Brown Paper with Ply 1Brown Paper with Ply 1 Per Layer

Spread / Lay Fabric Per Ply

Roll Change Per Layer

Deriving Per Meter Spreading TimeS. No. Operations Heavy

Weight ( In Min)

Stripes &

Checks( In Min )

Light Weight( In Min)

1 Brown Paper with Ply 1 15 40 15

2 Spreading Time( 100 Plies each of 6

Meters)

62 82 87

3 Roll Change 7 7 7

Total 84 129 109

Spreading Time Per Meter In Minute 0.14 0.22 0.18

Spreading Target

Fabric Spreading Time/ Meter( in Min )

Target/Hour @ 100 %(For a 6 Meter Lay )

Heavy Weight 0.1471

Stripes & Checks 0.2246

Light Weight 0.1855

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LAYERING

Layering Efficiency

Average Eff = 77 %

Limitations in LayeringRolls of same width have to be grouped before

Layering.Shrinkages & its Grouping is done before spreading

and fabric rolls should be easily made available at the time of Laying.

Roll change time has been averaged out because the number of Rolls to be changed in each Layer is variable.

Time Study is for a group of 3 Layer man.

CuttingMarker is spread on Layer and taping is done to

hold the marker tight.Target for Layer cutting is based on Cut Length of

Marker. Cut Length is the total perimeter of all the parts to

be cut in the marker.Cut Length details are optionally made available in

the Optitex software and must be chosen for the details to reflect in the Mini marker.

Cut Length Command

Deriving per Layer Cutting Time Based on Time Study, A Cutting Master can cut a

Perimeter/ Cut Length of 50 Meters.

Target (in Hours) = Total Cut Length / 50 + 12 min per layer for marker setting

For Eg. If a layer has Cut length of 85 meters, the time taken for a single cutting master shall be 85/50 = 1.70

Hours + 0.2 Hours / Layer for marker setting.

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CUTTING

Cutting Efficiency

Average Eff = 81 %

Limitations in CuttingLayer Height has not been taken into consideration.Various Shapes and contours of the pattern may

either slow down or speed up the cutting perimeter per hour.

The target of 50 meters per master per hour has been set taking into consideration an average of different fabric types & pattern shapes.

Numbering

Numbering time includes the time taken to change Sticker Rolls, adjusting the numbers in the machine, taking out and putting off the parts from/into cutting bags.

Numbering Target

Heavy weight – Denim, Tencel, Linen etc. Medium Weight – Cambric, Viscose, Rayon, Taffeta etc. Light Weight – Chiffon, Georgette, Gauze etc

Fabric Plies per Hour @ 100 %

Heavy Weight 3500

Medium Weight 3100

Light Weight 2800

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NUMBERING

Numbering Efficiency

Average Eff = 81 %

Limitations in NumberingEmbroidery Parts, Smocking Parts & Pin tuck

panels are stamped. Hence the timings would vary. If at some instance, More items are Running which

have majority of Parts to be Stamped, the target shall go down.

Numbering done on Tickli /Pattern extensions would need more attention and can increase the numbering time.

Fusing Fusing time studies have been done on fixed cuttings and

not on Block.

Fusing Target Based on Time Study

Process Batch of 25 panels ( in min )

Laying Fusible parts & fusing on Paper 3.80

Passing through fusing machine 0.80

Re bundling 1.00

Total 5.60

Fusing Target Avg time for fusing a single panel = 5.60/25 = 0.22 min

Fusing Target Per Person / Hour

Plies per Hour @ 100 %

268 ( Majority Cotton )/214 ( Majority Poly Chiffon )

2144/1712 plies per day

Avg time for fusing chiffon/ Georgette = 0.22*1.25 = 0.27 min

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FUSING

Fusing Efficiency

Average Eff = 86 %

Limitations in Fusing In Chiffon fabric & tricot Fusing the Time for fusing

goes up by 25 %.Hence, When Majority of item running are Light

Weight Polyester Based Fabric Like Chiffon & Georgette, Efficiency of Fusing department shall go down.

Recommended Block Fusing for Chiffon & Georgette Fabric.

Ratio of Layering/Cutting/Fusing SMV

50

10

40LAYERINGCUTTINGFUSING

36

7 30

27

LAYERINGCUTTINGRECUTTINGFUSING

With Re cuttingWithout Re cutting

ConclusionMeasurement & Target Setting of Cutting sub

processes helps in better monitoring and identifies areas for improvement.

Helps in effective utilization of man power even while running complex small run orders.

Measurement of every sub process puts pressure on individuals to perform and provides an easy control tool to the Cutting Head.