How to Increase Sewing Operator Efficiency?

 

 

In the garments manufacturing sector, a sewing operator plays an important role. Sewing operator efficiency has a great impact in achieving higher garments production, ultimately which helps to respect the shipping date. As its importance, today I will present here some important key points which help to increase the sewing operator efficiency.

 

Key Points for Increasing Sewing Operator Efficiency:

The following are the most important key points for increasing sewing operator efficiency.

 

1.    Training sewing operator,

2.    Motivation,

3.    Selection of expert operator for the critical process,

4.    Development of working methods,

5.    Set-up perfect machine layout,

6.    Continuous feeding to the operators,

7.    Remove unnecessary interruption during working,

8.    Set-up target for the operator,

9.    Avoid excessive overtime to the operator.

 

All the above points have discussed below:

 

1. Training sewing operator:

The operator is the main in garments manufacturing factory. It’s seen that less expert sewing operator takes more time but provides lower outputs in garments manufacturing. So, to increase sewing operator efficiency, training for sewing operators is a must.

2. Motivation:

Operator motivation plays an important role in increasing operator efficiency. So, to increase operator efficiency, factory authority should motivate the operator by arranging different cultural programs, a bonus for achieving targeted effort.

3. Selection of expert operator for the critical process:

It’s an important key point to increase operator efficiency. If the expert operator is selected for the most critical processes, then the rest of the process of that style will be easy and ultimately operator efficiency will be increased.

4. Development of working methods:

The working method should be developed by using work-study and motion study for increased operator efficiency. Sometimes it’s seen that, for a garment’s style, several unnecessary motions have been kept in line which ultimately decreases the operator efficiency. So, in that case, unnecessary motions should be removed for increased operator efficiency.

5. Set-up perfect machine layout:

A perfect machine layout for a particular style of clothing helps to complete 50% of total work for that style. So, a perfect machine layout is a must to increase operator efficiency. Perfect machine layout helps to minimize the material handling time as much as possible.

 

6. Continuous feeding to the operators:

It’s a very important one to increase operator efficiency. When a sewing operator has assigned with less work content then he has so much idle times. In this situation, you have to pass more works to him for increasing operator efficiency.

7. Remove unnecessary interruption during working:

It’s one of the important issues for decreasing operator efficiency. Sometimes it’s seen that the sewing operator is interrupted by supervisors and quality controllers, also submitted defective pieces to rectify, which consumes time and decreases operator efficiency. So, unnecessary interruption should be removed during working for increasing operator efficiency.

8. Set-up target for the operator:

Target set-up for the sewing operator is one of the useful factors for increasing sewing operator efficiency. In this case, first have to set an achievable target according to the sewing operator’s skill level, so that they can touch the given target. This system is very helpful for increased operator efficiency.

9. Avoid excessive overtime to the operator:

Excessive overtime to the operator can easily decrease operator efficiency. So, if you want to achieve better output from the sewing operator, then you must avoid excessive overtime to the sewing operator and confirm one day off weekly.

 

Work Study: Definition, Need and Advantages

After reading this article you will learn about:- 

1. Definition and Concept of Work Study 

2. Need for Work Study 

3. Advantages.

Definition and Concept of Work Study:

Work study, as defined by British Standard Institution, is a generic term for those techniques particularly ‘Method Study’ and ‘Work Measurement’ which are used in the examination of human work in all its contexts and which lead systematically to the investigation of all the factors which effect the efficiency of the situation being reviewed, in order to seek improvements.

Actually, work study investigates the work done in an organization and it aims at finding the best and most efficient way of using available resources, i.e., men, material, money and machinery. Every organization tries to achieve best quality production in the minimum possible time.

The time required to manufacture an item depends upon the manufacturing procedure; and one phase of work study known as Method study aims at finding the best possible manufacturing procedure which involves, least time and does not cause fatigue to the workers.

In brief, method study or motion study aims at finding the best way of doing a job. Method Study may be defined as the systematic investigation (i.e., recording and critical examination) of the existing method of doing a job in order to develop and install an easy, rapid, efficient, effective and less fatiguing procedure for doing the same job and at lower costs.

This is generally achieved by eliminating unnecessary motions involved in a certain procedure or by changing the sequence of operation or the process itself.

Once the method study has developed an improved procedure for doing a job, the work Measure­ment or Time Study will find the time allowed to complete the job by that procedure. Work Measurement may be defined as the application of different techniques to measure and establish the time required to complete the job by a qualified worker at a defined level of performance. The time necessary to complete a job is determined from number of observations.

Need for Work Study:

Principles of work study used to be employed even long ago, in order to explore improvements, when industry was simple and involved lesser problems; of course, a systematic procedure was not there. Today the industries with all their complexities and modernization naturally demand a more systematic approach like the work study in its present form.

Work study finds applications in:

1. Industries (Production operations, research and development),

2. Marketing, sales and distribution,

3. Offices, stores and warehouses,

4. Material handling,

5. Design,

6. Building and other constructions,

7. Transport,

8. Hospital,

9. Army, and

10. Agriculture, etc.

Advantages of Work Study:

(a) Uniform and improved production flow,

(b) Higher productive efficiency,

(c) Reduced manufacturing costs,

(d) Fast and accurate delivery dates,

(e) Better employee-employer relations,

(f) Better service to customers,

(g) Job security and job satisfaction to workers,

(h) Better working and other conditions, and

(i) Higher wages to workers.

Objectives of (or Advantages Obtained Through) Method Study:

(1) Improved working processes and standardized procedures,

(2) Better work place layout; neat and clean environments and working conditions,

(3) Less fatigue to operators,

(4) Better product quality,

(5) Effective utilization of men, materials and machinery,

(6) Efficient and fast material handling,

(7) Reduced health hazards,

(8) Efficient planning of the section, and

(9) Streamlined working procedures.

Objectives of (or Advantages Achieved Through) Work Measurement:

(5) Effective utilization of men, materials and machinery,

(6) Efficient and fast material handling,

(7) Reduced health hazards,

(8) Efficient planning of the section, and

(9) Streamlined working procedures.

Objectives of (or Advantages Achieved Through) Work Measurement:

(6) Decides realistic labor budgeting and provides a basis for standard costing system;

(7) Provides a basis for fair and sound incentive schemes; and

(8) Results in effective labor control.

Irrespective of the advantages mentioned above, the introduction of work study has always been looked by the supervisors, workers or union with suspicion. They probably feel insecure and think that work study will result in reduction in their salaries. Even otherwise a sudden change is never appreciated therefore workers and union should be taken into confidence and properly convinced before introducing work study.

Operation Analysis:

Operation Analysis is a detailed study of different operations involved in doing a work. Operation analysis becomes necessary in order to investigate the shortcomings of the existing method and to develop an improved procedure.

Operation analysis suggests, whether some elements, should be eliminated or combined or their sequence should be altered in order to obtain effective utilization of existing man­power and machinery with the minimum fatigue incurred by the workers. The analysis mainly considers the movements of the limbs and aims at finding a simpler and economical method of doing the job.

Before the procedural steps of a task are analyzed and the motions (of an operator) are studied or eliminated, an operation chart is constructed. Figure 9.7 shows an operation chart of the existing method of assembling nuts and bolts.

As a next step, the different motions involved are subjected to specific and detailed questioning with a view to eliminate unnecessary motions, and to arrange the remaining motions in a better sequence. Principles of motion economy serve as a very good guide in developing a better and improved method.

Besides assessing the present method a per the principles of motion economy, it is also subjected to following questions (whichever are applicable) with regard to:

(a) Worker:

1. Is he mentally and physically fit?

2. Does he incur unnecessary fatigue?

3. Does he need training to improve?

4. Does he get suitable salary?

(b) Set-Up:

1. Are tools and other equipment readily available?

2. Can the set-up be modified or can the number of set-ups be decreased?

(c) Material:

1. Is material of the proper specification i.e., composition, diameter, width, thickness of weight?

2. Can it be substituted by a less costly material?

3. Can scrap be minimized?

(d) Material Handling:

1. Can materials be transferred in big (unit) lots, thereby reducing the number of handlings?

2. Is it possible to avoid back tracking of the material?

3. Can the distances, by which the material is moved, be cut short?

(e) Operations:

1. Can some operations be eliminated?

2. Can some operations be made automatic?

3. How, re-sequencing of the operations will effect?

4. Is it possible to combine some operations?

(f) Tools and Fixtures:

1. Are they available in good condition?

2. Are they suitably located and prepositioned?

3. Is it advantageous to modify existing jigs and fixtures for better productivity?

(g) Working Conditions:

1. Is light and ventilation adequate?

2. Are the operations and working conditions safe?

3. Are facilities of wash rooms, etc., available?

Analysis of Motion:

The motions or movements of the limbs of a worker play a major part in the fabrication or manufacture of the products. By carefully observing a worker while he is doing an operation, a number of movements made by him which appear to be unnecessary and unproductive can be identified and eliminated.

Analysis of an operation, when carried out in terms of individual motions of a worker is known as motion analysis.

The purpose of motion analysis is to design an improved method which eliminates unnecessary motions and employs human efforts more productively. In doing so the principles of motion economy prove to be very helpful.

Steps involved in Motion Analysis are:

(a) Select the operation to be studied.

(b) List and chart various motions performed by the operator.

(c) Identify the productive and idle motions.

(d) Eliminate the unnecessary and non-productive motions.

(e) Redesign the existing operating procedure by employing minimum number of motions in the most appropriate sequence and in accordance with the principles of motion economy.

(f) Impart necessary instructions to the worker so that he develops proper habit cycle.

(g) Check once again the procedure in the light of step (e) above.

(h) The procedure may be standardized.

 

Procedure for Method Study: 6 Steps. Production Management

This article throws light upon the six steps involved in method study.
The steps are: 
1. Select 
2. Record 
3. Critical Examination 
4. Develop 
5. Install 

6. Maintain.

Step # 1. Select:

Select the work worth studying and define the objectives to be achieved. An objective may be to reduce the manufacturing cost, or to reduce bottlenecks or to reduce fatigue incurred by the workers in order to increase their efficiency.

Step # 2. Record:

Record all the relevant information pertaining to the existing method (if any) in details and in the form of a chart to obtain a more clear picture about the same.

Recording can be done with the help of following aids:

(a) Process Charts:

(i) Outline Process Chart:

An Outline Process Chart surveys and records an overall picture of the process and states only main events sequence-wise. It considers only (main) operations and inspections. Actually an outline process chart is the beginning of a detailed analysis.

 

Step # 3. Critical Examination:

Examine the recorded events critically and in sequence. Critical examination involves answering a number of questions. An activity can be eliminated, simplified or combined with another.

The basic questions are:

Purpose. – What is done?

Person. – Who does it?

Place. – Where is it done?

Means. – How is it done?

Sequence. – When is it done?

The above-mentioned five basic questions, individually are further subjected to enquiries like.

Why:

Why is it necessary, why he does it, why it is done there, why is it done by that method and why is it done at that time?

Alternative Ways of Doing:

What else could be done, who else could do it, where else it could be done, how else it could be done and when else it could be done.

Best Method of Doing:

What should be done, who should do it, where it should be done, how it should be done, and when it should be done.

Step # 4. Develop:

Develop the best method as resulted from critical examination and record it.

The developed method should be:

(i) Practical and feasible,

(ii) Safe and effective,

(iii) Economical, and

(iv) Acceptable to design, production control, quality control and sales departments.

Step # 5. Install:

Install the (best) developed method or the improved method. Installation involves three phases, namely-planning, arranging and implementing. During the first two stages the programme of installation (phase-wise) and a time table, are planned and the necessary arrangements of resources, equipment, tools and instructions to workers, over-time, etc., are made.

The implementation or actual installation involves the introduction of developed method as standard practice. Problems associated with the developed method should be carefully studied and remedied, if necessary. Installation phase is complete as soon as the new method starts working smoothly and satisfactorily and gives encouraging results (like saving in time, scrap reduction, etc.)

Step # 6. Maintain:

Maintain the new method, i.e., ensure the proper functioning of the installed method by periodic checks and verifications. The purpose of checks and reviews is to find if the method being practised is the same or it has deviated from the authorised one.

Reasons for deviation if any should be explored and the necessary changes may be made in the procedure being practised so that it reverts to the authorised one. Views of the workers, supervisors and other persons related with the authorised method can be of much help in exploring further improvements.