INDUSTRIAL ENGINEERING AND

MANAGEMENT
DIGITAL ASSIGNMENT-2
ARTHAM JAYANTH
17BME0275
SLOT- D1
PROF: DIBYAJYOTI GHOSH

METHOD STUDY ON PRODUCTION VOLUME

AND ASSEMBLY LINE EFFICIENCY
DEPARTMENT OF TEXTILE ENGINEERING
ISTANBUL, TURKEY
ABSTRACT:
Method Study which is one of the two essential components of work study is the best strategies that are utilized to deliver more
adequately with current machines and work with no requirement for speculation. In this examination, the tasks in blouse sewing
line are
broke down basically and the consequences of Method Study which is connected on four tasks are explored. Following that,
assembly line balancing is directed by utilizing Ranked Positional Weight Method considering task lengths which are taken from
method study and current activity times. The point of this exploration is to examine the impacts of method study on production
volume and assembly line productivity and to demonstrate the significance of method studies.
PRODUCT:
In this industry knitted blouses are manufactured. So we are going to discuss on how the industry improved the efficiency of
manufacturing these blouses.
A model of the blouse is given below.

WORK MEASUREMENT:
Time Study is used first to get the information on how to plan, design and organize the production process for maximum
efficiency.
They use a method called stopwatch technique to determine the standard time of production of blouse sewing.
These measurements are made to improve efficiency of operations in method study.
The measurements are done in (percentage-minute) and are converted to minute(percentage-minute/60) by taking the average of all
the times.

METHOD STUDY:
The efficiency of operations that can be increased are detected by the result of labour movement and their work techniques along
with time measurement.
Because of the improvements the factory works more smoothly and quickly.
OPERATIONS IN THE INDUSTRY:
(1) Front Part Puckering
(2) Sewing Shoulder
(3) Assembling Cuff to Sleeve
(4) Collar Overlock

Activities are shown as block or bar on a time scale in an activity chart. Times of the activities are determined according to length
of the bars.
However we have considered the sub operations too in these activity charts. Doing this gives us a deep knowledge on all processes
and makes it easy for us to improve method study.
The meaning of the symbols can be understood by the char given below.

1) Front Part Puckering:

When operation performing process is analysed, sub operations which are performed by operators are put in order as below
1. Getting front part-1 with two hands and place under the pressure foot.
2. Place the transparent elastic band under the pressure foot.
3. Sewing transparent elastic band to bottom of front part for 1 cm.
4. Getting ruler.
5. To measure 10 cm distance with the ruler on transparent elastic band.
6. Marking.
7. Leaving ruler.
8. Getting scissors.
9. Cutting transparent elastic band from marked point with the scissors.
10. Leaving scissors.
11. Sewing transparent elastic band to bottom of front part completely.
12. Getting the piece with one hand and leaving aside.

These sub operations performed for front part puckering before method study are given in a chart form below.

When the operations are analysed and method study is used, the sub operations are put in a new order for maximum efficiency.
The new order is given below.
1. Getting front part-1 with two hands and place under the pressure foot.
2. Place the transparent elastic band under the pressure foot.
3. Sewing transparent elastic band to bottom of front part-1 for 1 cm.
4. Marking according to ten centimeters distance which is pointed on the machine table before.
5. Getting scissors.
6. Cutting transparent elastic band from marked point with the scissors.
7. Leaving scissors.
8. Sewing transparent elastic band to bottom of front part-1 completely.
9. Getting the piece with one hand and leaving aside.
The above chart shows the sub operations performed after method study for front part puckering.
Conclusion:
As we can see from the charts that using the new method the process is done more quickly than the original method. By changing
the sub operation of transparent elastic band measurement, the 4,5 and 6 numbered sub operations are removed. As the result of
this the operation time decreases from 0.571 minutes to 0.462 minutes.

2) Sewing Shoulder:
When this operation was analysed we have classified it into some sub operations to make method study easier.
The sub operations original order is given below.
1. Getting front part with two hands and place under the pressure foot.
2. Getting back part with two hands and place under the pressure foot.
3. Sewing the front and back parts from shoulder.
4. Getting the sewn parts with one hand.
5. Getting scissors with one hand.
6. Making regulate (cut off the excess fabric).
7. Leaving scissors.
8. Getting the piece with two hand and leaving aside.

The chart of these operations before method study is given below.

After these sub operations were analysed and method study was used to improve the efficiency of sewing shoulder, we changed the
order of the sub operations and removed 4 sub operations. Even though we removed sub operations the final time to do shoulder
sewing decreased.
The order of operations after method study is given below.

1. Getting front part with two hands and place under the pressure foot.
2. Getting back part with two hands and place under the pressure foot.
3. Sewing the front and back parts from shoulder.
4. Getting the piece with two hand and leaving aside.
The chart of this new order is given below.
Conclusion:
We can notice from the above charts that when the recommended method is applied the time for the operation is very less
compared to the original method of operation.

The sub operations numbered 4,5,6 and 7 have been removed and usage rate of the machine has been increased by making another
operator perform at regular intervals at the machine which is a sub operation done after the shoulder sewing by the machines.
The operation time is decreased from 0.590 minutes to 0.383 minutes by eliminating the mentioned sub operations.

The operation time of the new operator is calculated to be 0.193 minutes.

Considering the recommended method the total operation time has been reduced to (0.383+0.193) minutes = 0.576 minutes.
While the machine was kept occupied for 0.590 minutes in the original method, it is kept occupied for 0.383 minutes by using
the recommended method.

3) Assembling Cuff to Sleeve:

This operation was analysed and divided into some sub operations.
The order of the sub operations is given below.

1. Getting cuff with one hand and place under the pressure foot.
2. Regulating selvages of cuff by superimposing them.
3. Sewing selvages of cuff parts by folding them in the middle.
4. Getting scissors.
5. Cutting the excess of thread.
6. Leaving scissors.
7. Leaving aside the cuff with one hand.
8. Getting sleeve with two hands and place under the pressure foot.
9. Getting cuff with two hands and place under the pressure foot.
10. Sewing cuff to sleeve
11. Leaving aside the sewn pieces with one hand.

The chart is as follows,

After using method study and analysed in a new way, the cuff preparation and assembling cuff to sleeve operations are given to
a new operator. The sub operation are put in new order.
Cuff preparing:
1. Getting cuff with one hand and place under the pressure foot.
2. Regulating selvages of cuff by superimposing them.
3. Sewing selvages of cuff parts by binding them in the middle.
4. Surplus tread trimming after every ten cuff preparing operations.
Assembling cuff to sleeve:
1. Getting sleeve with two hands and place under the pressure foot.
2. Getting cuff with two hands and place under the pressure foot.
3. Sewing cuff to sleeve
4. Leaving aside the sewn pieces with one hand.

We can understand from the activity charts given above, using the new method the operation is done in a shorter time than the
previous method. Because the cuff preparation and attaching cuff to sleeve operation are performed differently, the cuff
preparation operation lasts 0.151 minutes and attaching the cuff to sleeve operation lasts for 0.205 minutes. The total time is
(0.151+0.205)= 0.356. Previously before method study the operation was performed in 0.423 minutes. But now the operation is
performed in 0.356 minutes. Therefore a lot of time is saved.

4) Collar Overlock:
The collar overlock operation is performed after a collar part is sewed on the body part. Therefore regulations which are made
during sewing and moving collar part and body part simultaneously on the machine are substantially eliminated since it enables
to move collar part alone on the machine. Accordingly, the new method not only provides advantages in terms of time but also
enables to perform the operation by worrying the operator less.
The original sub operations are as follows,
1. Getting collar with two hands and place under the pressure foot.
2. Making overlock stitch.
3. Correction
4. Making overlock stitch.
5. Correction
6. Making overlock stitch.
7. Cutting the excess of thread 8. Leaving aside the piece with two hand.

The duration of performing the operations was analysed and the number of regulation process which the operator has to make
by using the previous method becomes 1 since the collar overlock process is performed before the collar part is sewed on the
body part.
Operations after method study are given below,

1. Getting collar with one hand and place under the pressure foot.
2. Making overlock stitch.
3. Surplus tread trimming after every ten collar overlock operations.
Looking at charts the new method is done in 0.292 minutes where as in the old method it took 0.394 minutes.

Final Conclusion:
From the above data, performing duration of machine and operator during the 4 operations is 1.978 minutes.
But after method study the total time is 1.493 minutes. Considering the efficiency it provides us 0.485 saving time during these
4 operations. Shoulder regulating operation is distinguished from shoulder sewing operation as it lets the machine not to wait
without performing for any operation.

ASSEMBLY LINE BALANCING IN THE FACTORY:

In assembly line balancing, method study is used. The method study used is Ranked Positional Weight Method. It is the best
method for assembly line balancing.
The longest duration of a work unit must surely be less than the duration of a work station. The duration of a work station also
cannot be longer than the cycle time.
The cycle time in assembly line balancing is accepted as 0.887 because of the above rule.
Loss of balance of assembly line, the total production and the total efficiency is calculated using the formula

LB = ((nC – ∑ Co) / nC)) 100

LE = (1 – LB) 100 ⃰
PA = T / C
Where:
LB is Loss of Balance, LE is Line Efficiency, C is Cycle Time, n is Total Number of Work Stations, Co is Average of Work
Station Time, PA is Daily Total Production Amount and T is Daily Total Production Time.

The list of operations to make these blouses are given in a table format which are considered before and after method study,
duration of operations, and machines used and operators.
Assembly line balancing explained using priority diagrams is given below and also ranked positional weight has been done.
The numbering of 17 processes can be understood by seeing the above table which has 17 processes.
Before method study:

After method study:

RESULTS:
All these operations were closely observed and suitable method study was applied. After method study the efficiencies are
examined.8.
Before the method study was applied there were 17 operations which took 8.957 minutes and after the method study was
applied there are 19 operations and it took 8.665 minutes. A total of 0.292 minutes have been saved.
Because a two single operations were divided into two operations each and are performed separately. This leads to increase
machine usage rate and also decreases duration of the operations.
To demonstrate the effect of the method study on production volume, the formulas which are given below are used.
PA = T / C
PA = (NOM x T) / TOT
Where:
PA is Daily Total Production Amount, T is Daily Total Production Time, C is Cycle Time, NOM is Number of Operator -
Machine and TOT is Total Operation Time.
Daily total production time is 540 minutes and cycle time is 0.887.
Daily total production amount (volume) is calculated by using the formula which is given above.
PA = 540 / 0.887 => PA = 608 pieces / day
When the production volume is 608, 15 operators - machines performed.
After the method study is applied, 13 operators- machines are needed to perform the operation.

If 15 operators and machines perform in assembly line by grounding duration of blouse production in both situations, daily
current output is expected to be as it is given below.
PA = (NOM x T) / TOT
PA = (15 x 540) / 8.957 => PA = 904 pieces / day (before method study)
PA = (15 x 540) / 8.665 => PA = 934 pieces / day (after method study)

As it can be understood from the calculation which is given above, as a result of method study, daily current output increases in
30. Based on total duration of production which is attained after method study, if the efficiency is assumed as %100, the
efficiency increased in 3.12% (100-(904/934) x100) according to the condition exists before the method study.

When the effect of the method study on assembly line efficiency is analysed, it can be seen that improvements of operations
and increase in duration have positive impact on assembly line efficiency. It can be concluded that 15 workstations are
necessary for assembly line balancing which is designed by considering present condition and assembly line efficiency is
calculated as 67.32%.

It can be seen from the study of assembly line balancing which is conducted after method study that 13 workstations are
necessary and assembly line efficiency is 75.15 %. This rate shows that assembly line efficiency increases in 7.83%.
However it is appeared that performing the operations “sewing shoulder” and “assembling cuff to sleeve” separately which are
normally performed as a single operation enables to decrease the number of work stations in assembly line balancing.

CONCLUSION:
This study was done to analyse how method study affects production line and assembly line efficiency and also tells us the
importance of method study.

The above analysis shows us that method study surely provides us with more efficiency in industries.
In the case of this industry the advantage of method study is given in the form of a table below.
Operations before method Operation time(min) Operations after method study Operation time(min)
study
Front Part Puckering 0.571 Front Part Puckering 0.462
Sewing shoulder 0.590 Sewing shoulder 0.383
Shoulder regulate 0.193
Assembling cuff to sleeve 0.423 Cuff preparation 0.151
Assembling cuff to sleeve 0.205
Collar overlock 0.394 Collar overlock 0.292
Total 1.978 1.686
Total sewing duration 1.978 1.493

Advantages of method study:-

1. Achieving same production volume by using less machines and operators
2. Operators’ performing the same operation in shorter time and with less effort.
3. Reduction of labor and energy costs by means of less usage of operators and machines.
4. Reduction of product cost as a result of reduction of all costs.
5. Saving on production area as a result of being need fewer machine and operators
6. Productivity growth
7. Producing more intelligently
8. Having more assembly line efficiency
9. Results of method studies being propulsive force for continuous development

Thank you