The analysis below of Work Study department is based on asurvey of ten factories and 300 people, commissioned by the
A comprehensive checklist was developed which covered everydepartment and each point on the checklist was awarded a value of 1 to 5points, 5 being considered an International benchmark. The points awarded wereadded and a percentage score was calculated. Priorities for improvement foreach department were established.
Work Study Department
In today's environment the need to improve productivity isessential. The Indian garment manufacturers must realize the importance ofusing scientific ways to analyse how best garments can be made and howmanufacturing procedures can be improved, workstudy is one of the most importanttools that can be used for this purpose. Workstudy is the most important toolfor controlling production and improving productivity. These departments arenot part of expenses but a part of investments.
The introduction of workstudy techniques into the industryis relatively new, there is a considerable shortage of good industrialengineers and the need for accelerated training in the techniques is important.Most companies do not have IE / workstudy departments and are losing a hugepotential for improvement. They have no means of measuring their performanceand are unaware of their competitive status.
Seven of the ten factories visited do not know theirperformance levels, and although the labour portion of the cost is around 25%there are great opportunities for improved profitability through improvedpractices and better methods. It is important to note that all of the majorplayers in the industry consider workstudy as a vital part of their operation.Garment factories will not survive in the future without well organizedmeasurement techniques; they must know their performance levels and constantlywork to improve them.
Standard Time and Target Setting
Many companies do not use standard time systems; targetsetting is based on guesswork and experience. Establishment of Standard timesand the development of the best method to manufacture is vitally important toimprove productivity. Every company that wishes to compete in the future mustrealize this. This chart clearly illustrates the benefits to factory efficiencyif standard times and well developed methods are used.
Method Analysis
Most of the companies are using poor methods, operators are left to establish best way to do the job, decide on the number of bursts of stitching, folding and unfolding of parts, unnecessary matching and additional handling, all of these motions add to the time it takes to manufacture the garment and should be eliminated. Method study can be implemented in any type of production system whether it is in-house or on a contract basis. Proper method analysis can improve productivity by at least 15%.
Workplace Layout
The management wants to fit as many machines in the factory as possible, reducing the scope for methods improvement. The space between machines is insufficient in many cases.
A good workplace layout will eliminate unnecessary motions and fatigue resulting in substantial increase in the efficiency of the operator. Just look at the picture alongside and think how efficiently you will be able to work 8 hours a day sitting in that posture.
Operation Sequence
Some of the production departments work without a properly planned or written operation sequence. This is a critical step in garment production and a mistake or negligence at this stage can result into huge losses later in terms of operator time, work content and quality.
Work Aids and Attachments
Use of work aids and attachments is insufficient. Many new and inexpensive attachments and folders are being continuously developed, it is vital that these developments are known to ensure a program of constant improvement. Many new and inexpensive attachments and folders are being continuously developed, it is vital that these developments are known to ensure a program of constant improvement.
Operator Monitoring
Most of the companies surveyed do not have the means to establish their performance against standard, so they have no idea where they stand. There are no proper measurements so their efficiency levels are at best a guess, it is impossible to understand how they will be able to continue to compete unless they have proper controls in place, and have established productivity improvement programs to move forward in the future
Cycle Checks
A simple technique aimed at establishing operator potential against their actual performance, this can be done by relatively inexperienced work study personnel and is a great aid to factory performance improvement. None of the companies perform cycle checks. The chart below shows the comparison between factories in Group A (with work study department) and Group B (without workstudy department) on various aspects of apparel production.
Looking at the comparison shown below it is obvious that group A factories are more productive than the group B factories. This fact is further strengthened when the overall factory survey results are compared. The factories in group A have a combined score of 61% for overall performance whereas factories in group B achieved a score of only 48%.
Work-study is the need of the hour and it is high time that the industry stalwarts understand its importance and its contribution to profitability.
Recommendations
1) Work study departments must be introduced in all companies.
2) Standard Times established.
3) Operator efficiency monitoring is essential.
4) All new operations must have a written method and the operator instructed in that method, this should also be used for training new operators.
5) Poor performers guided to improve their efficiency.
6) Investigation done to explore new attachments and folders.
7) Regular management meetings to establish the way forward and the month on month progress towards these aims carefully monitored.
Source: AEPC Weekly
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