Labour Productivity Improvement Using Line Balancing and Method Study Analysis

Abstract

Abstract: Labour productivity is one of the most essential performance indicators in garment manufacturing system. In the selected factory the planned production for one shift was 1200 pcs of trousers per line using 47 operators and the actual production was 718 pcs of trouser per shift. Due to this shipment delays were occurred frequently. So, this study aims to increase the labour productivity of a TCP type trouser sewing line through improving the method and balancing the line. Time study and method study techniques were used to get the required data. Using time study, the actual cycle time were recorded and using method study, value adding and non-value adding activities were identified according to the general sewing data (GSD system). Then these data were analysed using Ms. Excel, mathematical analysis and Arena software input analyser. Arena V14 full package software was used to represent the real system artificially and to analyse the queue of items, waiting time, daily output and work in progress (WIP). Scenarios were developed as shifting operators from one operation to other operation and method study analysis. Method study analysis gives a better improvement.

Key words: Labour productivity, Line balancing, Method Study, Garment production system