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Welcome. Title of the Thesis. Productivity Improvement of a Sewing Line in a Selected Company of Ready Made Garment Industry by Using Assembly Line Balancing Technique. Presented By Md. Anwar Hossen Reg. No. 2003334049 Md. Shakil Khan Reg. No. 2003334034.

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  1. Welcome

  2. Title of the Thesis Productivity Improvement of a Sewing Line in a Selected Company of Ready Made Garment Industry by Using Assembly Line Balancing Technique Presented By Md. Anwar Hossen Reg. No. 2003334049 Md. Shakil Khan Reg. No. 2003334034

  3. Now the business world is very dynamic and competitive. This competitive situation can only be managed by applying operations management tools. As example, for repetitive production system Assembly Line Balancing is very effective tool. Line balancing can ensure the improvement of: efficiency production rate productivity and Reduction of: idle time resource utilization production cost etc. Introduction

  4. Objectives • To evaluate the existing assembly line for finding the current status • To reduce idle time, if any • To improve productivity, if possible

  5. Research Methodology [page 13] The steps involved in case study are: Step 1: Determining the research questions Step 2: Selecting the cases and analysis techniques Step 3: Prepare to collect the data Step 4: Collect data in the field Step 5: Evaluate and analyze the data Step 6: Prepare the report

  6. Case Company • On the assembly process of Short Pant • In a manufacturing industry named “Mondol Fabrics Ltd.”, Nayapara, Kashimpur, Gazipur

  7. Tools & Techniques • Evaluation parameters of existing assembly process: • efficiency • idle time • production time • production rate • production cost & • productivity • Scientific technique “Six-Step Assembly Line Balancing” • Improvement analysis “Sequential Improvement Technique”

  8. Evaluation

  9. Six-Step Assembly Line Balancing [page 7] It has the following six steps: Step 1. Select task, estimate time & draw precedence diagram Step 2. Specify the daily output level & calculate cycle time Step 3. Calculate the minimum number of work centers Step 4. Develop an initial layout Step 5. Evaluate the current layout Step 6. If possible, improve the layout

  10. Time Study [page 3] Time study is the combination of a series of activities as follows: Step 1: Define the Task Step 2: Breaking the Job into Elements Step 3: Estimate the Required Number of Observation Step 4: Record the Times and Ratings of Performance Step 5: Average Observed Time Step 6: Normal Time Step 7: Allowance Step 8: Standard Time

  11. Collected Data [page 19] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - : : :

  12. Precedence Diagram [page 21]

  13. Initial Process Control Chart

  14. Evaluation Results [page 24]

  15. Improvement

  16. Reasons for Improvement • Efficiency 51.91 % bellow the standard • Productivity 1.102 close to minimum level • Existing line is unbalanced

  17. Sequential Improvement Technique [page 9] It has three sequential steps: Step 1: Withdrawal of Idle Resources Step 2: Redistribution of Tasks Step 3: Bottleneck Reduction a. By Existing Resources & b. By Additional Resources

  18. Summary after Withdrawal of Idle Resources [page 28]

  19. Summary afterRedistribution of Tasks [page 34]

  20. Manufacturing Cost after Improvement [page 41] With existing Resources:

  21. Comparative Summary after Improvement [page 41] With Existing Resources:

  22. Manufacturing Cost after Improvement [page 42] With Additional Resources:

  23. Comparative Summary after Improvement [page 42] With Additional Resources:

  24. Improvement in Terms of Money [page 43] By using Sequential Improvement Technique: Profit gain = 335820 TK Time saving = (17.77-12.67) days = 5.1 days By this time the industry can also gain, = (4576 piece/day)*(15.05 TK/piece)*(5.1 days) =351230 TK So, Total additional profit gain by improvement, = (335820+351230) TK = 687050 TK

  25. Achievement of Objectives

  26. Idle Time Reduction at Different Stages of Improvement

  27. Productivity Gain at Different Stages of Improvement

  28. Analytical Results Considering Different Allowance

  29. Productivity Gain for Different Allowance

  30. Efficiency Gain for Different Allowance

  31. Errors/Mistakes in Our Report

  32. Major Mistakes • In page 1: A world dominating business sector can fall down suddenly. (organization) • In page 4: Average observed valve. (value) • In page 15: After Introduction we have used STEP: ONE. (before STEP: ONE will be 4.2 Six-Step Assembly Line Balancing & after STEP: ONE will be 4.2.1 Time Study) • In page 25 & 28: The given control charts are wrong. • In page 34: We have used 39.3 % allowance. (20 %). • In page 37: Typing mistake for value of SSV & SMV.

  33. Limitations of this Thesis

  34. Limitations • Assumption about the current method. • Omission of performance rating. • Omission of cross study for different product. • Lack of our experience.

  35. Thank You

  36. Questions ???

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