time study in Arvind garment

AN INTERNSHIP REPORT

ON

TIME STUDY

CARRIED OUT

AT

ARVIND LIMITED

UNDER THE GUIDANCE OF

Mr. Srinivas Nayak (washing head )

Mr.Bibhraj Bhusan Rout (Manager: IE & planning )

BY :-

CHANDRA SHEKHAR KUMAR

About The Arvind export, Bangalore

• Arvind denim holds the position of 3rd largest

producer in the world.

• Arvind caters a quality market of Europe,US,

West Asia & the Far east .

BRANDS AT ARVIND

• Own brands

–Ruff & Tuff

–Flying Machine

–Newport

- Excalibur

• Joint Venture Brands

- Tommy Hilfiger

- Lee

-Wrangler

-Nautica

-Riders

-Wrangler Hero

• Licensed Brands

- Arrow

-Izod

-Sansabelt

-Uspa

-Pier Cardin Paris

-Cherokee

Time and Motion study

Time & Motion Analysis Objectives are

• The improvement of processes and procedures.

• The improvement of plant, office or service arealayout.

• Economy in human effort to the reduction ofunnecessary fatigue.

• Improvement in the use of materials, machines andmanpower.

Calculation of SAM through Time Study

• Basic Time = Cycle Time X performance Rating

(cycle time – total time taken to do all works needed

to complete one operation, i.e. time from pick up part

of first piece to next pick up of the next piece).

• Standard allowed minutes (SAM) = Basic minute +

allowances.

http://www.onlineclothingstudy.com/2011/05/concept-of-operators-performance-rating.html

WASHING DEPARTMENT

Washing department is mainly divided into two different sectors

1.Dry process

2.Wet process

Stitching

Laser Whickering Laser

Hand sanding Resin

Tacking Tying Crinkle & curing(3-D effect)

Wet Process Hand Sanding

Material flow in Wet Process

Dry Process

Semi wash

1-Enzyme wash

2-Stone wash

3-bleach wash

4-sponze wash

Hydro

Dryer

PP Spray

cont......

• Grinding

Final wash

Hydro

Dryer

Ozone gas

Audit

Dispatch

DRY PROCESS

• The distressed jeans that we see around

everywhere undergo a wide variety of wet as

well as dry treatments to get the desired

effects.

• Destroying denims is as much an art as it is a

technique.

LASER

• The laser fading process is acknowledged as a very

strong alternative compared to the conventional

physical and chemical processes used for aged-worn

look on denim fabrics.

• The beams from a CO2 (10.6 µm) laser was used for

the fading of denim fabrics.

Laser effect

LASER SYSTEM TECHNOLOGY v alue tome Nonev alue time Operator Nonoperator

Left side of garment-1st Right side of garment-2nd

pickup t he gar men t f r om st an dLaser design pat t er n f loat in g 2 2

Adjust t he piece a/ c t o designswit ch on by leg 13 13

Laser design act ion per f or m 7

Laser design pat t er n f loat in g 3

swit ch on by leg 1 1


Laser design pat t er n f loat in gAdjust t he piece a/ c t o design 3



Laser design pat t er n f loat in g 3



T ot al t ime 2 8 2 7 18 0

Per cen t age 5 0 . 9 0 % 4 9 . 0 9 % 3 3 % 0 %

ACTIVITIES FOR LASER SYSTEM TECHNOLOGY

Observe Time

t ime r equir ed r at in g % n or mal t ime al l owance st an dar d t ime

Readin g 1 exp. 4 5 9 0 4 0 . 5 2 0 4 8 . 6

Readin g 2 exp. 4 5 9 1 4 0 . 9 5 2 0 4 9 . 14

Readin g 3 exp. 4 4 9 3 4 0 . 9 2 2 0 4 9 . 10 4

Readin g 4 exp. 4 7 8 9 4 1. 8 3 2 0 5 0 . 19 6

Readin g 5 exp. 4 3 9 4 4 0 . 4 2 2 0 4 8 . 5 0 4

Readin g 6 exp. 4 8 8 6 4 1. 2 8 2 0 4 9 . 5 3 6

Readin g 7 exp. 4 9 8 7 4 2 . 6 3 2 0 5 1. 15 6

Readin g 8 exp. 4 6 9 0 4 1. 4 2 0 4 9 . 6 8

Readin g 9 f r e. 6 2 7 0 4 3 . 4 2 0 5 2 . 0 8

Readin g 10 f r e. 6 8 6 5 4 4 . 2 2 0 5 3 . 0 4

Avr age t ime 5 0 . 10 3 6

CALCULATION FOR HANDS REQUIRMENT

LASER SYSTEM TECHNOLOGY

Z S H W Out put

Input 7000 80 8 1 10.9375

here z No. Of Garment processed

s System 1,(144) & System 2,( 80)

w no. of worker required in each cycle=1

h total time in houres

RECOMONDATION :-

• For reducing Non valuable & valuable time some effective trainingprogram should be adopted.

• All operators are not following the correct manner way of doing laser.They need to be given a proper training.

• Regular monitoring is needed there.

• Unnecessary entrance should be prohibited in laser department as theyare distracting operator that may lead to error in garment.

• Helper should be given training so that they can be utilized duringlunch period as laser activity is not a sophisticated process and it canbe done by them .This will lead to increase in production.

WHISKERING

• On Denim, whiskers is nothing but the worn out lines

/ impression generated by natural wearing on hip &

thigh area.

• There are many designs & pattern available.

• This is being done manually with help of sharp edge

Emery paper rolled on fine wood stick or pasted on

plastic material.

Whiskering Effect

http://www.denimsandjeans.com/wp-content/uploads/2009/10/clip-image003.jpg






Activities For Wishkering Process

ACT I VI T ES FOR HAND WI SHKERI NG VALUE T I M E NONVALUE T I M E OPERAT ORNONOPERAT OR

T ake t he gar men t f r om gar men t st an d 3 3

T ake t he gar men t in mould t able & Adjust 16 16

Per f or m mouldin g act ion in f r on t side of f ir st leg 3 1 3 1

T ake of f t he gar men t f r om mould t able 3 3

Put t he gar men t in gar men t st an d 2 2

T ake t he gar men t f r om gar men t st an d 3 3

T ake t he gar men t in mould t able & Adjust 15 15

Per f or m mouldin g act ion in f r on t side of secon d leg 3 7 3 7

T ake of f t he gar men t f r om mould t able 3 3


T OT AL T I M E 6 8 4 7 115 0

Per cen t age 5 9 . 13 % 4 0 . 8 0 % 10 0 % 0 %

Observe Time

MOULDING PROCESS

time required rating %normal time allowance standrade time

experianceReading 1 106 80 84.8 20 101.76

Reading 2 107 79 84.53 20 101.436

Reading 3 102 81 82.62 20 99.144

Reading 4 92 89 81.88 20 98.256

Reading 5 86 94 80.84 20 97.008

Reading 6 96 88 84.48 20 101.376

Reading 7 92 91 83.72 20 100.464

Reading 8 88 92 80.96 20 97.152

fresherReading 9 119 70 83.3 20 99.96

Reading 10 130 65 84.5 20 101.4

AVRAGE 99.7956


M OULDING PROCESS

Z S H W Output

Input 5000 31 8 2 40.32258

here z No. Of Garment processed

s style (heavy31/medium39/lighter45)



RECOMONDATION

• For reducing Non valuable & valuable time someeffective training program should be adopted.

• Moulding table height should be adjustable.

• Workers are working at around 70% efficiency.

• Mask should be compulsory.

• Hand gloves should be compulsory.

HAND SANDING

• Hand sand is step which is generally being done in rigid

form of garments to get distress look

• Locations can be front thigh & back seat or its can be

overall / global application as per Standard.

• Emery paper is being used to scrape the garments in

particular placement & design.

ACTIVITIES FOR HAND SANDING PROCESS ACTI VI TES FOR HANDSANDI NG VALUE T I M E NON VALUE T I M EOPERATOR NONE OPERATOR

lif t t he gar men t f r om gar men t st an d 3 3

t ake t he gar men t in man equin 2 5 2 5

swit ch on t he air bulb 5 5

per f or me han dsan din g in f r on t side of f ir st leg 5 5 5 5

per f or me han dsan din g in f r on t side of secon d leg 4 5 4 5

r ot at e t he man equin wit h t he help of swit ch 5 5

per f or me han dsan din g in back side of f ir st leg 5 8 5 8

per f or me han dsan din g in back side of secon d leg 4 7 4 7

Release t he air f r om man equin 4 4

Take of f t he gar men t f r om man equin 3 3


TOTAL T I M E 2 0 5 4 8 2 5 3

PERCENTAGE 8 1% 19 % 10 0 %

Observe Time

HAND SANDI NG PROCESS

t ime r equir ed r at in g % n or mal t ime al l owance st an dr ade t ime

exper ian ceReadin g 1 3 . 5 9 0 3 . 15 2 0 3 . 7 8

Readin g 2 4 . 0 8 8 0 3 . 2 6 4 2 0 3 . 9 16 8

Readin g 3 3 . 5 5 9 0 3 . 19 5 2 0 3 . 8 3 4

Readin g 4 3 . 5 7 8 9 3 . 17 7 2 0 3 . 8 12 7 6

Readin g 5 3 . 3 1 9 2 3 . 0 4 5 2 0 3 . 6 5 4 2 4

Readin g 6 3 . 3 3 9 2 3 . 0 6 4 2 0 3 . 6 7 6 3 2

Readin g 7 3 . 4 5 9 1 3 . 14 2 0 3 . 7 6 7 4

Readin g 8 3 . 5 3 8 9 3 . 14 2 2 0 3 . 7 7 0 0 4

f r esher Readin g 9 4 . 6 7 0 3 . 2 2 2 0 3 . 8 6 4

Readin g 10 5 6 5 3 . 2 5 2 0 3 . 9

AVRAGE 3 . 7 9 7 5 5 6


HAND SANDING PROCESS

Z S W H Output

Input 15000 14 1 12 89.285714

here

z No. Of Garment processed



h total time in houre

RECOMONDATION

• For reducing Non valuable & valuable time some effectivetraining program should be adopted.

• Mobile should be prohibited for machine operator.

• Many of Operators are doing scrapping in bending position because allthe operator are not of same height that is why it may lead to tirednesssoon so there is a need to change in structure in front of the machine.

• We can make an adjustable arrangement so that each operator canadjust the machine according to their height.

CRINKLING AND CURING

• For high quality 3D crunching / whiskers, the two

most important criteria are temperature and control of

cycle.

• Presses should be equipped with high-heat, cast

aluminium heads or with supplementary electrical

heaters to give a processing temperature of

approximately 150 – 180 degree centigrade.

• This temperature is crucial as it starts the curing

process and controls the effects.

• This process consists of passing the infra red light on

to the jeans for 6 min.

3-D Crinkle Effect

ACTIVITIES FOR 3-D EFFECT

3 - D EFFECT CRI NKEL value t ime Non value t ime Oper at or Non oper at or

M an , 1 seat in gM an , 2 seat in gM an , 3 st an din gM an , 4 st an din g

wait in g f or m/ c door open in g 15 15

I dle I dle swit h on t he valvet ake t he gar men t f r om st an d 5 5

I dle I dle t ake of f t he f r om m/ ct ake on t he r ar men t in t he m/ c 10 10

hold t he por t ion of gar men t whear 3 - D ef f ect & swit ch on t he valve 9 9

per f or m 3 - D cr in kel ef f ect on gar men t 4 0 4 0

I dle I dle 5 5

I dle I dle 10 10

hold t he por t ion of gar men t whear 3 - D ef f ect & swit ch on t he valve 9 9

per f or m 3 - D cr in kel ef f ect on gar men t 4 0 4 0

Tot al t ime 8 0 6 3 14 3 0

per cen t age 5 5 . 9 4 % 4 4 . 0 4 % 10 0 % 0 %

Observe Time

t i me r equi r edr at i ng %nor mal t i me al l owance standr ade t i me

exper i anceReadi ng 1 145 90 130.5 20 156.6

Readi ng 2 143 91 130.13 20 156.156

Readi ng 3 157 84 131.88 20 158.256

Readi ng 4 151 88 132.88 20 159.456

Readi ng 5 153 85 130.05 20 156.06

Readi ng 6 147 89 130.83 20 156.996

Readi ng 7 151 88 132.88 20 159.456

Readi ng 8 163 80 130.4 20 156.48

f r esherReadi ng 9 185 70 129.5 20 155.4

Readi ng 10198 65 128.7 20 154.44

AVRAGE 156.93

3-D EFFECT (M ACT EC)


3-D EFFECT

Z S H W Out put

Input 5000 65 8 2 19.23076923

here


s Ifrared=65/2,Mactek=99/4,Bohamia=56/4

w no. of worker required in each cycle


RECOMONDATION

• For reducing Non valuable & valuable time some

effective training program should be adopted.

• One person should make separate piece.

• This will make them specialised & reduce cycle time

PP SPRAY

• Potassium permanganate spray is done on jeans to

take a bright effect on sanding area.

• One important thing about potassium permanganate

spray is it is usually a sporting process to increase the

effect of sanding.

• Potassium permanganate solution is sprayed on

blasted area of jeans garment with the help of normal

spray gun.

P P Spray Effect

Activities For P P Spray

value time nonvalue time operatore nonopretor1 nonopretor2

Operator Nonoperator Nonoperator

spray front side take off the garmenttake the garment 14 14 3 3

Rotate the garmentput the gar. In standtake on the gar. In booth arm 3 3 7 8

spray back side idle idle 13 13

Total time 27 3 30 10 11

Percentage 90% 10% 100% 33.33% 36.66%

Observe Time P P SPRAY PROCESS

t ime r equir ed r at in g % n or mal t ime allowance st an dr ade t ime

exper ian ceReadin g 1 3 2 9 0 2 8 . 8 2 0 3 5

Readin g 2 3 0 9 2 2 7 . 6 2 0 3 3

Readin g 3 2 9 9 4 2 7 . 2 6 2 0 3 3

Readin g 4 3 1 9 1 2 8 . 2 1 2 0 3 4

Readin g 5 3 2 9 0 2 8 . 8 2 0 3 5

Readin g 6 3 0 9 2 2 7 . 6 2 0 3 3

Readin g 7 2 8 9 7 2 7 . 16 2 0 3 3

Readin g 8 2 9 9 5 2 7 . 5 5 2 0 3 3

f r esherReadin g 9 4 0 7 0 2 8 2 0 3 4

Readin g 10 4 3 6 5 2 7 . 9 5 2 0 3 4

AVRAGE 3 3


P P SPRAY

Z S H W Output

Input 12000 80 8 3 56.25

here





RECOMMANDATION

• For reducing Non valuable & valuable time someeffective training program should be adopted.

• Only 4 helpers to be used on a booth because 2 peopleinsert the pieces and one person take out the garment andone person just stand near the stand to hang the garment.That should be avoided.

• The person who is taking out the garment can directlyhang on the hanger.

• There are total 4 booths so we can save total 4 workers.

WET PROSESS

• Denim washing is the aesthetic finish given to thedenim fabric to enhance the appeal and to providestrength.

• With dry denim, however, such fading is affected bythe body of the person who wears the jeans and theactivities of their daily life.

• This creates what many feel to be a more natural,unique look than pre-distressed denim.

Types of Denim Wash

1. Mechanical washes

- Stone wash

- Micro sanding

2. Chemical washes

- Denim bleaching

- Enzyme was

- Acid wash

-stone wash

ENZYME WASH

• It is environmentally friendly wash.

• It involves the Application of organic enzymes that

eat away at the fabric, i.e. the cellulose.

• When the desired colour is achieved, the enzymes can

be stopped by changing the alkalinity of the bath or

its temperature.

• Post treatment includes final rinsing and softening

cycle.

Enzyme Wash Effect

HYDRO EXTRACTION

• A high rotating machine for 4-6 min .due to

centrifugal force water is extracted from the garment

so that it might take less time while drying .

• Total machine =5

• Capacity =8-100

• Man power =2/machine and two helper

HYDRO EXTRACTION

• ACTIVITEIS TIME IN (SEC)

• LOADING 280

• DOOR CLOSED 13

• RUNNIGN 420

• DOOR OPEN 5

• UNLOAD 192

• TOTAL 910

RECOMONDATION

• During running time both the operator are doing

nothing except standing near the machine .

• One complete cycle takes around 15 min i.e. in one

hours 30 min they are idle and in one shift 240 min

means 50 % time they are idle.

• They can be asked to bring the trolley during idle

time from final wash as final wash operator remains

busy and have to handle 3-4 machines

TRAINING PROGRAM FOR OPERATORS

• DEVISING A TRAINING SCHEDULEMETHODOLGY

• Operators are divided into experience level 0-2 months (trainees) 2-5 months 5-8 months 8-12 months Over 1 year

• Ten operators from each experience level are taken and there average hourly production is taken

• A graph is formulated after analyzing the above readings.

• Trainees with two months or less experience weregiven light sanding styles or easy styles to workon.

• To form a common result the average hourlyproduction of each level experience is

• Based on the assumption that 10 garments peroperator (for full scrapping) is the optimumrequirement a training schedule with differentmodules is derived.

OPERATORS WITH TWO MONTHS OR LESS EXPERIENCE

OPREATOR

EXPERIENCE LEVEL AVERAGE HOURLYPRODUCTION

AKHILESH SINGH DEEP NARAYAN SINGH

0-2 months10.5

DILWAR HUSSAIN LASKAR MOIN UDDIN

0-2 months9

JAYED AHMED LASKAR MONIR UDDIN LASKA

0-2 months9

KUMDEO TURI BASUDEO TURI 0-2 months 7.3MUSTAK AHMED BARBHUIYA ALI

RAJA0-2 months

9.1NAZMUL HUSSAIN LASKAR JOMIR

UDDIN0-2 months

9.5SUROJIT NAMASUDRA SUDHANYA

CHANDRA0-2 months

9

UTTAM KUMAR ROY RANJAN ROY 0-2 months 6.44VIKAS KUMAR RAJWA GOVIND

RAJWAR0-2 months

10.5

VISHAL PANDAY PAWAN PANDAY 0-2 months 11.33

AVERAGE HOURLY PRODUCTION 9

OPERATORS WITH EXPERIENCE LEVEL 2 – 5 MONTHS

NAME OF THE OPERATORS EXPERIENCE LEVEL AVERAGE HOURLY PRODUCTION

ABDU SALAM CHOUDRY 2-5 Months 15ABU BAKKAR JOYNUL HAQUE

LASKAR2-5 Months

12.25BUDDHADEV MONDAL

MEGNATH MONDAL2-5 Months

14.45

KARTIK GORAI SUFAL GORAI 2-5 Months 11.55NAREN MONDAL MONI MOHAN

MONDAL(LATE)2-5 Months

12.6SAHADATH HUSSAIN HANEEF

MIYA2-5 Months

11

SAPAN DUTT MANI DATT 2-5 Months 7.67SUKUMAR MISHRA ANANDA

MISHRA2-5 Months

9.5

TARUN MISHRA BABLU MISHRA 2-5 Months 12

AVERAGE HOURLY PRODUCTION 11.78

OPERATORS WITH EXPERIENCE 5-8 MONTHS

OPERATORS EXPERIENCE LEVEL AVERAGE HOURLY PRODUCTION

ABDUL HUSSAIN BARBHURIYA NAZEM UDDIN

5 – 8 MONTHS 6

ARVIND RAJNARAYAN 5 – 8 MONTHS 10.45

ASHIM KUMAR MONDAL 5 – 8 MONTHS 10

BILAL AHMED LASKAR ILLAS ALI LASKAR

5 – 8 MONTHS 10.39

BECHU KUMAR RAJNARAYAN 5 – 8 MONTHS 10

VIRABAL VIJAYABAHADDUR 5 – 8 MONTHS 13.6

SUBASH VERMA BHOLA VERMA

5 – 8 MONTHS 8.6

AVERAGE HOURLY PRODUCTION

10

OPERATORS WITH EXPERIENCE 8-12 MONTHS


HALIM UDDIN BARBHURIYA SAWKAT ALI

8 – 12 MONTHS 7.5

PAVITHRA RAMESH 8 – 12 MONTHS 11

RAJDEV MOOLCHAND 8 – 12 MONTHS 10.75

SARVAN PARAS 8 – 12 MONTHS 12

MUKESH DATTA SAPAN DUTTA 8 – 12 MONTHS 6.8

CHANDRAMMA RAJU 8 – 12 MONTHS 10

D MANOJ KUMAR DASARATH 8 – 12 MONTHS 9

DILWAN HUSSAIN 8 – 12 MONTHS 8

AVERAGE HOURLY PRODUCTION 9.5

OPERATORS WITH OVER 12 MONTHS OF EXPERIENCE


B PADMA SHANKARE GOWDA

OVER ONE YEAR 13.5

BAPAN MONDAL SUNIL MONDAL

OVER ONE YEAR 12

MUKESH DATTA SAPAN DUTTA

OVER ONE YEAR 13.5

SALEEMA NIZAM OVER ONE YEAR 10

HARISH GURUSIDDAIAH OVER ONE YEAR 8

K C PRASANNA CHANDREGOWDA

OVER ONE YEAR 10

K KRISHNA KENCHAIAH OVER ONE YEAR 12.5

AVERAGE HOURLY PRODUCTION

11.5

EXPERIENCE LEVEL

STYLE AVERAGE HOURLY

PRODUCTION

STANDARDIZED RATING

STANDARDIZED HOURLY

PRODUCTION

0-2 MONTHS (TRAINEES)

EASY STYLES/LIGHT

SCRAPPING

9 0 PERCENT 9

2-5 MONTHS LIGHT SCRAPPING /

MEDIUM SCRAPPING

11.78 30 PERCENT 15

5-8 MONTHS MEDIUM SCRAPPING / FUL

BODY SCRAPPING

10 60 PERCENT 16

8-12 MONTHS MEDIUM SCRAPPING / FUL

BODY SCRAPPING

9.5 60 PERCENT 15.2

1 YEAR OR MORE MEDIUM SCRAPPING / FUL

BODY

11.5 60 PERCENT 18.4

0

2

4

6

8

10

12

14

16

18

20

0-2 MONTHS(TRAINEES)

2-5 MONTHS 5-8 MONTHS 8-12 MONTHS 1 YEAR ORMORE

Series1

0 1 2 3 4 5 6 7 8 9 10 11 12

• Based on the above graph it can be concluded

that a training period of 45 days is required for

the training

CONCLUSION

• For reducing Non valuable & valuable time some effective training program should be adopted.

• The effective training program should be adopted for better efficiency and productivity.

• Under utilization of department due to frequent materiel shortage.

• Piece Rate system should be adopted for better efficiency & productivity.

• Working equipments should be ergonomically design specially Moulding department.

THANKS

Technology

time study in Arvind garment