3. SUBMITED TO:
KAMRUL HASAN
LECTURER, AMMT, SMUCT
SUBMITED BY:
1. MD.EMDADUL HAQUE
121011195(LEADER)
2. MD.TAREQ ALAM 121011163
3. AL-AMIN 121011178
4. TARIKUL ISLAM 121011157
5. MD.ALI HASAN SUVO 121011190
6. MD RAJIBUL RAHMAN SUJON 121011306
7. MD HUMAUN KABIR 121011170
8. MUINUL ISLAM 121011242
9. NURUN 12101
SEMESTER: 5TH; BATCH: 18TH; GROUP: ‘A’
3
4. ACKNOWLEDGMENT
AT THE PREFACE, WE WOULD LIKE TO THANK THE
ALMIGHTY ALLAH. THEN WE WANT TO THANK OUR
FAVORITE AND HONORABLE TEACHER KAMRUL
HASAN OF THIS IDEAL UNIVERSITY, WHO GIVE US THE
BIG OPPORTUNITY TO MAKE UP EXTRA ORDINARY
ASSIGNMENT LIKE THIS. THIS IS A HUGE EDUCATIONAL,
INTERESTING EXPERIMENT OF OUR LIFE THAT WE HAVE
EVER PERFORMED.
WE HOPE THAT THIS ASSIGNMENT WILL BE SERVING THE
RIGHT PURPOSE IN FUTURE, SO THAT WE THINK OUR
ATTEMPT ATTAIN AN ENCOURAGING SUCCESS.
4
5. CONTENTS
5
S.L TOPIC PAGE NO
01 INTRODUCTION 06
02 OBJECT OF THE STUDY 07
03 METHODOLOGY OF THE STUDY 08
04 LIMITATION OF THE STUDY 09
05 OVERVIEW OF THE ORGANIGATION 10-11
06 PRODUCTIVITY IMPROVEMENT TECHNIQUE USING
WORK STUDY IN RMG SECTOR
12-22
07 PROBLEMS / CHALLENGES 23
08 PRODUCTIVITY IMPROVEMENT TECHNIQUE USING
COMPUTERIZATION
24
09 PRODUCTIVITY IMPROVEMENT TECHNIQUE USING
QUALITY CIRCEL
25-26
10 PRODUCTIVITY IMPROVEMENT TECHNIQUE USING
JAPANESE MANAGEMENT
27
11 PRODUCTIVITY IMPROVEMENT TECHNIQUE USING
MOTIVATION
28
6. INTRODUCTION
BANGLADESH IS A DEVELOPING COUNTRY.RMG PLAY A
VITAL ROLE IN OUR ECONOMY. THE APPAREL INDUSTRY
IS ONE OF THE PILLAR INDUSTRIES OF BANGLADESH.
BANGLADESH IS THE 3RD LARGEST APPAREL
EXPORTING COUNTRY IN THE WORLD. THE READYMADE
GARMENTS (RMG) INDUSTRY IS THE LARGEST SINGLE
ECONOMIC SECTOR IN BANGLADESH WHICH
CONTRIBUTES TO 76% OF NATIONAL EXPORTS AND 90%
OF MANUFACTURING GOODS EXPORTS .
THE GARMENT INDUSTRY IS HIGHLY LABOR-INTENSIVE
AND EMPLOYS APPROXIMATELY TWO MILLION
WORKERS, OUT OF WHICH 90 PER CENT ARE WOMEN
THEREFORE, BANGLADESH HAS AROUND 70 MILLIONS
OF AVAILABLE LOW COST WORKERS WHO COULD BE
EASILY TRAINABLE AND ENGAGED IN THE APPAREL 6
8. METHODOLOGY OF THE STUDY
METHODOLOGY ARE TWO TYPES
1. PRIMARY DATA
2. SECONDARY DATA
BOTH PRIMARY & SECONDARY DATA WE USED TO
COMPLETE OUR ASSIGNMENT WORK.
PRIMARY DATA
BY A QUESTIONNARIRE THROUGH MERCHANDISER
AND FLOOR IN-CHARGE.
FACE TO FACE CONVERSATION WITH THE TOP
OFFICIALS.
COLLECT FACTORY DATA LIKE PO SHEET,DAILY
PRODUCTION,PITCH DIAGRAM ETC.
SECONDARY DATA 8
9. LIMITATION OF THE STUDY
THE SURVEY WAS CONDUCTED IN A VERY SHORT TIME SO WE
WERE NOT ABLE TO COLLECT MORE INFORMATION.
ONLY THE BIG AND THE REPUTED GARMENTS COMPANY
CONSIDER HERE AS SAMPLE.
THE QUESTIONNAIRE CONTAINS SOME QUESTIONS THAT, IF
ANSWERED PROPERLY, MIGHT DAMAGE THE COMPANY`S
IMAGE. IN THIS TYPE OF QUESTIONS THE RESPONDENTS
MIGHT PROVIDE SOCIALLY ACCEPTABLE ANSWERERS. THIS
RISK WAS UNAVOIDABLE.
ANOTHER LIMITATION OF THIS STUDY IS THE PERSON`S
PRIVATE INFORMATION WERE NOT DISCLOSING SOME, DATA
AND INFORMATION FOR OBVIOUS REASONS, WHICH COULD
BE VERY MUCH USEFUL.
LACK OF EXPERIENCE IN THIS FIELD.
LACK OF PROPER AUTHORITY TO CONDUCT THE INTERVIEW
PROGRAM. 9
10. OVERVIEW OF THE ORGANIGATION
INTRODUCTION OF INDENT FASHION LTD
INDENT FASHION LTD ESTABLISHED IN 2012 FOR ALL KIND OF KNITTED T-SHIRT, POLO
SHIRT, PIJAMA SET, JACKET AND ALL KIND OF FLEECE ITEMS. OUR TARGET IS TO
PROVIDE BEST POSSIBLE SERVICE TO SECURE THE ORDER, SAMPLING PROGRAM BY
THE HIGHLY SKILLED TEAM. ON TOP OF THAT, EACH AND EVERY PROGRAM IS
CLOSELY MONITORED Y THE MANAGEMENT/ TEAM AT DAILY BASIS TO AVOID
MISTAKES AND MADE THE CUSTOMER MORE RELAXED. KEEPING IN MIND, WE
UPDATE IN ACCORDANCE WITH THE CONTEMPORARY FASHION AND MADE HANDY
COLLECTION [FOR EACH SEASON]. THE UNDISPUTED POWER OF TEAM MOVE
TOGETHER WITH A VIEW TO “TURN IDEAS INTO REALITY FOR THE RETAILERS AND
WORKING TOGETHER BY EXCHANGING THE IDEAS, INNOVATION, EXCELLENCE,
PERFORMANCE, SKILLS, RELIABILITY, INFORMATION AND ALSO VALUED THE COST
OF THE CUSTOMER BY CREATING GOOD WORKING ENVIRONMENT.”
10
11. FACTORY DETAILS
FACTORY DETAILS : 100% EXPORT ORIENTED KNIT SEWING GARMENTS IN
THE DIFFERENT LOCATIONS.
GARMENTS PRODUCTS : ALL KINDS OF KNIT ITEMS IN BASIC & FANCY, LIKE T-
SHIRT, POLO-SHIRT, TURTLE NECK, SHORTS, SWEAT
SHIRT, JACKET, TANG-TOP, TROUSERS ETC.
EXPORTING COUNTRY : USA, EUROPE, UK
PRODUCTION CAPACITY : GARMENTS: BASIC STYLE : 6000/DAY
POLO SHIRT : 4000/DAY
FLEECE JACKET : 3,000/DAY
FLEECE BOTTOM : 3,000/DAY
TANG-TOP : 6,000/DAY
WORK FORCE : OFFICE : 20
GARMENTS SECTION : 200
TOTAL : 220
GARMENTS SECTION : TOTAL SEWING MACHINE : 160 SETS
TOTAL SEWING LINES : 4
TOTAL FACTORY : 17,500 SQFT.
FINISHING SECTION : ELECTRIC SYSTEM IRON WITH VACUUM 8 SET 11
12. PRODUCTIVITY IMPROVEMENT TECHNIQUE
USING WORK STUDY IN RMG SECTOR
WORK STUDY IS AN IMPORTANT MANAGEMENT TOOL TO ACHIEVE HIGHER
PRODUCTIVITY. IT IS RELATED TO HUMAN WORK, METHOD OF DOING WORK
AND STANDARD OF PERFORMANCE. THE SURVIVAL OF ANY ORGANIZATION
IS DEPENDENT ON USE OF LATEST TECHNOLOGY AND EFFICIENT METHODS
OF PRODUCTION. TO IMPROVE EFFICIENCY OF PRODUCTION IT NEEDS
EFFECTIVE UTILIZATION OF PLANT, EQUIPMENT AND LABOR. THIS CAN BE
ACHIEVED BY USING WORK STUDY WHICH STUDIES METHOD AND
EVALUATE THE PERFORMANCE. IT DIVIDES WORK INTO SMALLER
ELEMENTS, STUDIES IT, AND REARRANGES IT TO GET SAME OR GREATER
EFFICIENCY AT REDUCED COST. INTERNATIONAL LABOR ORGANIZATION
(ILO) DEFINES WORK STUDY AS THE TECHNIQUE OF METHOD STUDY AND
WORK MEASUREMENT EMPLOYED TO ENSURE THE BEST POSSIBLE USE OF
HUMAN AND MATERIAL RESOURCES IN CARRYING OUT A SPECIFIED
ACTIVITY. IT IS ALSO A MANAGEMENT SERVICE BASED ON METHOD STUDY
AND WORK MEASUREMENT USED IN EXAMINATION OF HUMAN WORK
LEADING TO INVESTIGATION OF ALL THE RESOURCES THAT EFFECT
EFFICIENCY AND ECONOMY OF SITUATION TO AFFECT IMPROVEMENT.
OBJECTIVE OF WORK STUDY
- EXPLAIN MECHANIZATION AND AUTOMATION RELATIVE TO GENERAL- AND
SPECIAL-PURPOSE MACHINES
- EXAMINE THE BASIC COMPONENTS OF SEWING MACHINES AND WORK12
13. TECHNIQUES OF WORK STUDY
THE AMOUNT OF WORK IN A GIVEN JOB IS
REFERRED TO AS WORK CONTENT. THE WORK
STUDY CONSISTS OF TWO TECHNIQUES:
METHOD STUDY:
METHOD STUDY IS THE SYSTEMATIC RECORDING
AND CRITICAL EXAMINATION OF EXISTING AND
PROPOSED WAYS OF DOING WORK. IT IS
CONCERNED WITH THE REDUCTION OF WORK
CONTENT OF A JOB OR OPERATION.
WORK MEASUREMENT:
WORK MEASUREMENT IS THE APPLICATION OF
TECHNIQUES DESIGNED TO ESTABLISH THE TIME
FOR A QUALIFIED WORKER TO CARRY OUT A
SPECIFIED JOB AT DEFINED LEVEL OF
13
14. METHOD STUDY
THE METHOD INVOLVES SYSTEMATICALLY
FOLLOWING SIX STEPS
14
16. TIME STUDY
TIME STUDY IS A METHOD OF MEASURING WORK FOR
RECORDING THE TIMES OF PERFORMING A CERTAIN
SPECIFIC TASK OR ITS ELEMENTS CARRIED OUT UNDER
SPECIFIED CONDITIONS. AN OPERATOR DOES SAME
OPERATION (TASK) THROUGHOUT THE DAY. TIME STUDY
HELP TO DEFINE HOW MUCH TIME IS NECESSARY FOR
AN OPERATOR TO CARRY OUT THE TASK AT A DEFINED
RATE OF PERFORMANCE.
HOW TO CONDUCT TIME STUDY?
STEP 1: PREPARATION
STEP 2: TIME CAPTURING
STEP 3: CALCULATION OF BASIC TIME
STEP 4: CALCULATION OF STANDARD TIME 16
18. CALCULATION OF PRODUCTION CAPACITY (IN
PIECES): ONCE WE HAVE ABOVE INFORMATION USE
FOLLOWING FORMULA TO CALCULATE
PRODUCTION CAPACITY.
PRODUCTION CAPACITY (IN PIECES) = (CAPACITY IN
HOURS*60/PRODUCT SAM)*LINE EFFICIENCY
FOR EXAMPLE: SUPPOSE A FACTORY HAS 8 SEWING LINES AND EACH
LINE HAS 25 MACHINES. TOTAL 200 MACHINES AND WORKING SHIFT IS
10 HOURS PER DAY. TOTAL FACTORY CAPACITY PER DAY IS 2000 HOURS
(200 MACHINES * 10 HOURS). IF FACTORY IS PRODUCING ONLY ONE
STYLE (SHIRT) OF SAM 25 MINUTES AND USED ALL 200 MACHINES DAILY
PRODUCTION CAPACITY AT 50%
= (2000*60/25)*50% PIECES
= (2000*60*50) / (25*100) PIECES
= 2400 PIECES
EFFICIENCY CALCULATION FORMULA:
EFFICIENCY (%) = [TOTAL MINUTE PRODUCED BY AN OPERATOR/TOTAL
MINUTE ATTENDED BY HIM *100]
WHERE,
TOTAL MINUTES PRODUCED = TOTAL PIECES MADE BY AN OPERATOR X
SAM OF THE OPERATION [MINUTES]
TOTAL MINUTES ATTENDED = TOTAL HOURS WORKED ON THE MACHINE
X 60 [MINUTES] 18
19. ON-STANDARD OPERATOR EFFICIENCY
OPERATOR EFFICIENCY CAN BE EXPRESSED IN MORE SPECIFIC WAYS, LIKE
‘ON-STANDARD EFFICIENCY’ INSTEAD ‘OVER-ALL EFFICIENCY’. AN OPERATOR
MAY BE ATTENDING ALL HOURS IN A SHIFT BUT IF HE HAS NOT BEEN GIVEN
ON-STANDARD WORK TO DO IN ALL HOURS, HE WILL NOT BE ABLE TO
PRODUCE MINUTES AS PER HIS CAPABILITY AND SKILL LEVEL. IN THIS CASE,
TO KNOW OPERATOR’S ON-STANDARD EFFICIENCY FOLLOWING FORMULA IS
USED.
OPERATOR ON-STANDARD EFFICIENCY (%) = TOTAL MINUTE PRODUCED
/TOTAL ON-STANDARD MINUTE ATTENDED *100%
WHERE,
TOTAL MINUTES PRODUCED = TOTAL PIECES MADE BY AN OPERATOR X
SAM OF THE OPERATION [MINUTES]
TOTAL ON-STANDARD MINUTE ATTENDED = (TOTAL HOURS WORKED – LOSS
TIME) X 60 [MINUTES]
EXAMPLE: AN OPERATOR WAS DOING AN OPERATION OF SAM 0.50
MINUTES. IN AN 8 HOURS SHIFT DAY HE PRODUCES 400 PIECES. OPERATOR
WAS IDLE ‘WAITING FOR WORK’ FOR 30 MINUTES AND HIS MACHINE BROKE
DOWN FOR 15 MINUTES IN HOURS SHIFT. SO ACCORDING TO THE
EFFICIENCY CALCULATING FORMULA, THAT OPERATOR’S ON-STANDARD
19
20. PITCH TIME
PITCH TIME: IN INDUSTRIAL ENGINEERING, PITCH TIME IS A RATIO
OF TOTAL SAM OF GARMENT AND NUMBER OF OPERATIONS TO BE
SET FOR THE STYLE. OR
PITCH TIME = GARMENT SAM/NO. OF OPERATIONS.
PITCH TIME IS USED FOR LINE SETTING AND CALCULATING
PRODUCTION TARGET FOR THE LINE.
PITCH DIAGRAM: A GRAPHICAL PRESENTATION OF INDIVIDUAL
OPERATION’S TIME (SAM) AND PITCH TIME ON A SAME CHART IS
CALLED PITCH DIAGRAM. FOR EXAMPLE SEE THE FOLLOWING
CHART (FIG.1). AT THIS CHART ON X-AXIS OPERATIONS NAME AND
ON Y-AXIS TIME VALUE IS DEPICTED. THE BLUE LINE IS SHOWING
INDIVIDUAL OPERATION SAM AND RED LINE IS SHOWING PITCH
TIME.
20
22. B.P.T=TOTAL S.T/NO. OF OPERATOR
=189/14=13.5
U.C.L=B.P.T/0.85
=13.5/0.85=15.89
L.C.L=(2*B.P.T)-U.C.L=(2*13.5)=11.11
TARGATE PRODUCTION=SHIFT*NO. OF
OPERATOR*85%/STANDARD TIME
=8*14*3600*85%/189=1813 PCS
FACTORY
EFFICIENCY=B.P.T*100/H.P.T=13.5*100/24
=56%
EXPECTED PRODUCTION=SHIFT*NO. OF
OPERATOR*FACTORY EFFICIENCY/ STANDARD
TIME
=8*3600*14*56%/189 22
23. PROBLEMS / CHALLENGES
ORGANIGATION ARE NOT HELPFUL.
SUFFICIENT RECORDS, FACTS AND FIGURES
ARE NOT AVAILABLE.
NARROWED SCOPE OF THE REAL ANALYSIS.
UNDERSTANDING PROBLEM .
CONFUSED ABOUT WHAT WE ASK & WHAT
THEY ANSWERED.
SOME ORGANIGATION ARE FLOWWED S.T &
REST OF THEM ARE NOT FOLLOWED.
23
25. PRODUCTIVITY IMPROVEMENT TECHNIQUE
USING QUALITY CIRCEL
1. QUALITY CIRCLES MUST BE STAFFED ENTIRELY BY VOLUNTEERS.
2. EACH PARTICIPANT SHOULD BE REPRESENTATIVE OF A
DIFFERENT FUNCTIONAL ACTIVITY.
3. THE PROBLEM TO BE ADDRESSED BY THE QC SHOULD BE
CHOSEN BY THE CIRCLE, NOT BY MANAGEMENT, AND THE CHOICE
HONORED EVEN IF IT DOES NOT VISIBLY LEAD TO A MANAGEMENT
GOAL.
4. MANAGEMENT MUST BE SUPPORTIVE OF THE CIRCLE AND FUND
IT APPROPRIATELY EVEN WHEN REQUESTS ARE TRIVIAL AND THE
EXPENDITURE IS DIFFICULT TO ENVISION AS HELPING TOWARD
REAL SOLUTIONS.
5. CIRCLE MEMBERS MUST RECEIVE APPROPRIATE TRAINING IN
PROBLEM SOLVING.
6. THE CIRCLE MUST CHOOSE ITS OWN LEADER FROM WITHIN ITS
OWN MEMBERS.
7. MANAGEMENT SHOULD APPOINT A MANAGER AS THE MENTOR OF25
26. QUALITY CIRCEL 12. FOLLOW UP AND
REVIEW
11. REGULAR
IMPLEMENTATION.
10. TRIAL
IMPLEMENTATION.
9.FORESEEING PROBABLE
RESISTANCE
8. DEVELOPING
SOLUTION.
7. DATA ANALYSIS.
6. ROOT CAUSE
ANALYSIS.
5. IDENTIFICATION OF
CAUSES.
4. ANALYSIS OF THE
PROBLEM.
3. DEFINITION OF THE
PROBLEM.
2.SELECTION OF THE
PROBLEM.
1.IDENTIFICATION OF
PROBLEM.
26
27. PRODUCTIVITY IMPROVEMENT TECHNIQUE USING JAPANESE
MANAGEMENT
THE REASONING BEHIND IMPLEMENTING 5S IN THE
WORKPLACE AND WHY SORTING IS IMPORTANT .
1. HOW TO ARRANGE THE WORKPLACE TO MAKE IT MORE
EFFICIENT AND PRODUCTIVE .
2. WHY AND HOW TO MAKE ITEMS EASILY IDENTIFIABLE .
3. THE IMPORTANCE OF KEEPING WORK AREAS AND ITEMS
CLEAN AND OF REGULARLY INSPECTING THEM FOR FAULTS.
4. THE THREE STEPS INVOLVED IN STANDARDISING . 27
29. CONCLUSION
BANGLADESH, TRADITIONALLY KNOWN FOR JUTE & TEA
EXPORTS, HAS RECENTLYATTRACTED ATTENTION FOR
READYMADE GARMENTS & LEATHER EXPORTS.BANGLADESH
IS THE BEST PLACED IN THE REGION FOR TEXTILE &
GARMENTS INDUSTRYDUE TO CHEAP LABOUR & FAVORABLE
TRADE STATUS WITH THE EU. CURRENTLY BANGLADESH IS
NOW SECOND LARGEST READY MADE GARMENTS
MANUFACTURER AFTER CHINA, BY THE NEXT FIVE YEARS
BANGLADESH WILL BECOME LARGEST READY MADE
GARMENTS MANUFACTURER.SO ACHIVE THE 1ST PLACE WE
NEED TO DO HARD WORK BOTH WORKER AND THE
GOVERNMENT.INVESTIGATE THE NEED FOR THE
GOVERNMENT TO WORK CLOSELY & DIRECTLY WITH
INDUSTRY TO MAKE SURE STANDARDS ARE CORRECTLY
IMPLEMENTED, THE WORLD BANK SAID FIRMS MIGHT ALSO
REQUIRE SUPPORT TO REARRANGE FACTORIES OUT OF
RESIDENTIAL AREAS AND INTO PURPOSE-BUILT FACILITIES
WITH SAFER WORKING ENVIRONMENT.
FAINALY WE CAN SAY THAT WORK STUDY IS VERY IMPORTANT29
30. REFERENCES
A. J. S. M. KHALED, (2008), FIRST EDITION,; E-MAIL: A_J_SM-
KHALED2HOTMAIL.COM,” WORK STUDY AND
PRODUCTIVITYIMPROVEMENT TECHNIQUES IN APPAREL
INDUSTRIES.
MARTIN CHRISTOPHER, (2006-2007), LOGISTICS AND SUPPLY
CHAIN MANAGEMENT: STRATEGIES FOR REDUCING COST AND
IMPROVING SERVICE-SECOND EDITION, PP. 15.
LIN, S. M. A. MOORE, D. H. KINCADE, AND C. AVERY,
(2002), “DIMENSION OF APPAREL MANUFACTURING STRATEGY
AND PRODUCTION MANAGEMENT. INTERNATIONAL JOURNAL OF
CLOTHING SCIENCE AND TECHNOLOGY 14(1), 46-60.
THE PRODUCTIVITY IMPROVEMENTS: FOCUSING ON SMOOTH FLOW
OF INFORMATION & PRODUCTION... 27
KANIGEL ROBERT (1996), “FREDERICK TAYLOR’
DROLET, J. R., 1989, SCHEDULING VIRTUAL CELLULAR
MANUFACTURING SYSTEMS, PH.D. THESIS, SCHOOL OF INDUSTRIAL
ENGINEERING, PURDUE UNIVERSITY, WEST LAFAYETTE, INDIANA.
DIAZ-SANTILLAN, E., AND MALAVE, C. O., 2004, SIMULATED
ANNEALING FOR PARALLEL MACHINE SCHEDULING WITH SPLIT
JOBS AND SEQUENCE-DEPENDENT SET-UPS. INTERNATIONAL
JOURNAL OF INDUSTRIAL ENGINEERING - THEORY APPLICATIONS
AND PRACTICE, 11(1), 43-53. 30
