Line Balancing

Prepared By :
Prepared By : Mazadul Hasan sheshir

ID: 2010000400008
13th Batch (session 2009-2013)
Department : Wet Processing Technology
Email: mazadulhasan@yahoo.com
Blog : www. Textilelab.blogspot.com (visit)
Southeast University
Department Of Textile Engineering

I/A 251,252 Tejgaon Dhaka Bangladesh
Total Textile Process at a Glance
Introduction
Line and work cell balancing is an effective tool to improve the
throughput of assembly lines and work cells while reducing
manpower requirements and costs. Assembly Line Balancing or
simply Line Balancing (LB) is the problem of assigning operations to
workstations along an assembly line, in such a way that the
assignment be optimal in some sense. LB has been an optimization
problem of significant industrial importance: the efficiency difference
between an optimal and a sub-optimal assignment can yield
economies (or waste) reaching millions of dollars per year.
LB is a classic Operations Research (OR) optimization problem,
having been tackled by OR over several decades. Many algorithms
have been proposed for the problem. Yet despite the practical
importance of the problem, and the OR efforts that have been made
to tackle it, little commercially available software is available to help
industry in optimizing their lines.
LINE BALANCING (Process Organization)
The Line Balancing is to design a smooth production flow

by allotting processes to workers so as to allow each
worker to complete the allotted workload within an even
time It is a system where we meet the production
expectations and we can find the same amount of work in
process in every operation at any point in the day.
Reasons to have balance the production

line
(1) Keeping inventory costs low results in higher net
income.
(2) Keeping normal inventory levels lets the operator work
all day long giving him/her the opportunity to earn more
money by increasing his/her efficiency.
(3)Keeping the line balanced lets the supervisors
improve other areas because they can use their time
better.
(4) Balanced production keeps prices low which turns into
repeat sales.
(5) Balanced production means better production planning.
Balancing Method
The most basic methods are the Time Study,
Bottle Neck Process Theory and Data Collection and
Analysis.
How do we start balancing the production

line?
Well we can start by determining how many operators for
each operation are needed for a determined level of
production. After this we need to determine how much WIP
we need to anticipate production problems. Recommended
WIP is 1-hour inventory level for each operation. A good
range would be from 30 min to 120 min inventory level.
There are 3 rules for balancing

(1) Have at least hour of WIP for
each operation
(2) Solve problems before they become any larger

(3) Meet production goals by keeping every operator
working at their maximum capacity
Time Study
What is time study?
Time study is a work measurement technique
for recording the time of performing a certain
specific job or its element carried out under
specific condition and for analyzing the data so
as to obtain the time necessary for an operator
to carry out at a defined rate of performance
Time Study
Time study is a method of direct observation. A trained
observer watches the job and records data as the job
is being performed over a number of cycles.
Time study equipment
the stop watch in general, two types of watch are
used for time study.
Fly back
Continuous
These watches may be used any of the following time
scales
Seconds
Decimal minutes
Decimal hours
SMV
SMV time that is allowed to perform the job
satisfactory.
SMV = Basic time + Allowances
Standard Minute Value
SMV = B.T + Allowances
Basic Time
The basic time for the operation is found by applying
concept of rating to relate the observed to that of a
standard place of working.
Calculated as follows:
Basic time = observed time * observed rating
100
(BT = Observed time * Observed Rating= A
constant)
100
Example..
Rating
50
75
100
125
Observed time1.2
0.8
0.6
0.5
Basic Time
1.2*50 0.8*75 0.6*100 0.5*125
100
100
100
100
0.6
0.6
0.6
0.6
SMV calculation
Element description
Obser
rating
Obser.
time
Basic
Time
Freq.
Basic
Time/Gmt
Get bundle and sort parts
95
0.32
0.304
1/30
0.010
Match pocket flap to lining
105
0.11
0.116
1/1
0.116
Sew round flap
100
0.48
0.480
1/1
0.480
Trim threads and turn out

flap
58
0.35
0.298
1/1
0.298
Top stitch flap
90
0.56
0.504
1/1
0.504
Close bundle and place

aside
110
0.23
0.253
1/30
0.008
Total
1.416
Total basic time/garment (brought forward) 1.416

Add machine attention allowances 7%
7% of (0.480 + 0.504) = 0.07 x 0.984 = 0.069 0.069
Basic time + MAA (1.416 + 0.069)
1.485
Add personal needs and relaxation allowances 14%

14% of 1.485 = 0.14 x 1.485 = 0.208
0.028
Standard minute Value (SMV) = Basic time + all

allowances
(SMV)
= 1.485 + 0.208 = 1.693
Production Planning
Load and capacity Planning
Successful planning requires knowledge of two
variables to determine the time required to
manufacture a contract.
Load How much work we are putting on a section
Capacity How much work a section is capable of
completing
In an ideal situation
>> Load = Capacity
Load and capacity

LOAD Contract size x Work content
Capacity The amount of work the factory
or section is capable of doing.
The scheduling rule

Balance load and capacity
Arrange the programmed of work so that the
load can be achieved
Use common units standard minutes
Balancing & Capacity

Load
Capacity
Uncertainty about the

number of garments
to be sold Demand?

number of operators and
performance
Speculation?
Total numbers
Prediction?
Attendance hours
Uncertainty about
work content
Absenteeism
Standard minute
value
Measured
Estimated
Performance
Learning curve
equipment
Availability
Reliability
Pitch Time
Reference value for synchronization in the division of
labor is called Pitch Time (PT). Pitch Time provides
average time allotted to each worker.
Bottleneck Process:
The time at which the longest time is required is called bottleneck Process The
state of line organization should be evaluated as Organization Efficiency
Using the
pitch time and Bottleneck Process Time.
Organization Efficiency (%) =
Pitch Time
________________________
x 100
Bottleneck Process Time

100
= ______ X 100
140
= 71.4 % (For the aforementioned case study)
Pitch Diagram in the form of Column Graph
Work
Allotment
Time
How to reduce the number of

bottleneck processes
(1) Investigate the relation between the bottleneck process and its
previous and subsequent processes to correct the line organization.
(2) Investigate whether it is possible to further divide the process.
(3) Conduct the motion study for work improvement.
(4) Make improvements to equipment, jig and tools.
(5) Mechanize the manual work.
(6) Change the positions of workers.
(7) Investigate the modification to the machining specifications.
(8) Make it a rule to lend the worker in charge of the bottleneck
process a helping hand
Control limit
Control limit
Pitch Time
Upper Limit = _________________________ X 100
Target organization efficiency
= 0.85
= 117.6 Seconds
Lower Limit
= 2 x Pitch Time Upper Limit

= 2 x 100 117.6
= 82.4 Seconds
Data Collection
One Composite Mills Ltd.
Capacity check sheet U-1 (Line: 2)
Style no: 29694
Target: 180pcs/ hour
Order quantity: 18694
Buyer: Collins
Description: T-Shirt
Type: Basic
27-03-2013
SL
Operation Name
Operator Name & ID M/C

type
Actual
Process
output per time
hour
(3pcs)
Avg. time
with 20%
allowance
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
Shoulder join-1
Shoulder join-2
Neck rib folding & servicing
Neck rib edge joint
Neck joint
Piping shoulder to shoulder-1
Piping top stitch shoulder to shoulder-1
Sleeve joint-1
Sleeve joint-2
Arm hole position zigzag top stitch-1
Side seam-1
Side seam-2
Side seam-3
Side seam position zigzag top stitch-1
Arm hole point position tack(2T)-1
Sleeve hem-1
Sleeve hem-2
Roman
Tuni
Johura
Mukul
Sajida
Taslima
Arif
Rekha
Alal
Hasina
Shapla
Helena
Afsana
Laboni
Ashiq
Parvin
Mukta
Alpona
Khaleda
Hameed
Sayeed
Hasan
138
212
200
225
212
120
157
189
124
68
72
116
113
65
68
72
116
129
106
116
113
103
26
17
18
16
17
30
23
19
29
53
50
31
32
55
53
50
31
28
34
31
32
35
17371
19021
20568
20918
3357
2199
19799
20954
3011
850
19930
18332
20922
20145
19659
3360
2124
19564
20878
7495
20871
20414
O/L
O/L
O/L
P/M
O/L
F/L
F/L
F/L
F/L
O/L
O/L
F/L
F/L
O/L
O/L
O/L
F/L
F/L
P/M
P/M
F/L
F/L
22,24,21
16,13,14
16,14,16
14,12,12
15,13,14
26,23,25
18,20,18
16,15,17
24,25,24
44,46,43
42,40,43
28,26,23
26,29,27
48,44,45
44,42,45
41,42,44
27,25,26
23,24,22
28,30,27
24,25,23
25,28,28
30,28,29
28-03-2013
SL
Operation Name

type
Actual
Process
output per time
hour
(3pcs)
Avg. time
with 20%
allowance
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
Shoulder join-1
Shoulder join-2
Neck rib edge joint
Neck joint
Sleeve joint-1
Sleeve joint-2
Side seam-1
Side seam-2
Side seam-3
Sleeve hem-1
Sleeve hem-2
Roman
Tuni
Johura
Mukul
Sajida
Taslima
Arif
Rekha
Alal
Hasina
Shapla
Helena
Afsana
Laboni
Ashiq
Parvin
Mukta
Alpona
Khaleda
Hameed
Sayeed
Hasan
144
200
180
257
200
129
138
189
144
67
73
120
116
62
69
68
120
129
113
129
113
100
25
18
20
14
18
28
26
19
25
54
49
30
31
58
52
53
30
28
32
28
32
36
17371
19021
20568
20918
3357
2199
19799
20954
3011
850
19930
18332
20922
20145
19659
3360
2124
19564
20878
7495
20871
20414
O/L
O/L
O/L
P/M
O/L
F/L
F/L
F/L
F/L
O/L
O/L
F/L
F/L
O/L
O/L
O/L
F/L
F/L
P/M
P/M
F/L
F/L
21,22,20
14,16,14
17,15,18
11,14,12
15,14,16
24,23,21
21,24,22
18,15,16
20,22,21
44,44,46
41,42,40
27,24,25
26,27,26
47,48,50
44,42,43
46,44,42
27,23,26
22,25,23
30,25,25
24,22,23
28,26,27
30,29,30
29-03-2013
SL
Operation Name
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
Shoulder join-1
Shoulder join-2
Neck rib edge joint
Neck joint
Sleeve joint-1
Sleeve joint-2
Side seam-1
Side seam-2
Side seam-3
Sleeve hem-1
Sleeve hem-2

type
Actual
Process
output per time
hour
(3pcs)
Avg. time
with 20%
allowance
Roman
Tuni
Johura
Mukul
Sajida
Taslima
Arif
Rekha
Alal
Hasina
Shapla
Helena
Afsana
Laboni
Ashiq
Parvin
Mukta
Alpona
Khaleda
Hameed
Sayeed
Hasan
129
200
200
225
225
133
144
200
144
67
73
124
116
64
67
65
116
124
106
124
100
100
28
18
18
16
16
27
25
18
25
54
49
29
31
56
54
55
31
29
34
29
36
36
17371
19021
20568
20918
3357
2199
19799
20954
3011
850
19930
18332
20922
20145
19659
3360
2124
19564
20878
7495
20871
20414
O/L
O/L
O/L
P/M
O/L
F/L
F/L
F/L
F/L
O/L
O/L
F/L
F/L
O/L
O/L
O/L
F/L
F/L
P/M
P/M
F/L
F/L
21,23,24
13,14,17
15,13,18
12,13,13
14,12,13
25,20,22
19,23,21
17,14,15
23,21,20
45,42,47
41,43,40
27,23,22
28,24,26
47,49,45
43,46,45
44,46,47
28,27,24
25,22,24
29,26,28
24,23,24
27,33,29
29,31,29

Style no: 29694
Date: 27-03-20013
Buyer: Collins
Description: T-shirt
Type: Basic
27-03-20013
SL
Operation Name

type
Actual
Process
output per time
hour
(3pcs)
Avg. time
with 20%
allowance
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
Shoulder join-1
Shoulder join-2
Neck rib edge joint
Neck joint
Sleeve joint-1
Sleeve joint-2
Side seam-1
Side seam-2
Side seam-3
Sleeve hem-1
Sleeve hem-2
Kajoil
Rehena
Reema
Sima
Any
Salma
Rina
Bulbuli
Laboni
Amena
Asadul
Anwara
Johir
Reena
Nupur
Khadija
Mannan
Nargis
Tara
Rabea
Rajib
Rojina
131
180
192
206
180
120
131
169
137
58
68
103
107
55
56
56
102
120
102
115
93
96
26
19
18
17
19
29
26
20
25
60
50
34
32
62
61
61
34
29
34
30
37
36
19865
20617
20306
20827
20640
22037
20616
22038
19044
20145
20839
5037
20928
19509
19486
9384
20698
18289
22060
19874
21013
3361
O/L
O/L
O/L
P/M
O/L
F/L
F/L
F/L
F/L
O/L
O/L
F/L
F/L
O/L
O/L
O/L
F/L
F/L
P/M
P/M
F/L
F/L
21,21,23
14,16,17
13,14,17
13,14,15
15,17,17
23,24,25
20,21,26
17,17,16
25,20,19
50,51,49
43,40,44
30,27,28
24,29,29
53,54,48
50,53,49
51,51,52
28,28,29
24,24,25
28,29,26
23,24,29
30,33,31
29,30,30
28-03-2013
SL
Operation Name
Operator Name & ID
M/C
type
Actual output Process time

per hour
(3pcs)
Avg. time
Avg. time with
20% allowance
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Shoulder join-1
Shoulder join-2
Neck rib edge joint
Neck joint
Sleeve joint-1
Sleeve joint-2
Side seam-1
Side seam-2
Side seam-3
Sleeve hem-1
Sleeve hem-2
Body hem
Label make
Kajoil
Rehena
Reema
Sima
Any
Salma
Rina
Bulbuli
Laboni
Amena
Asadul
Anwara
Johir
Reena
Nupur
Khadija
Mannan
Nargis
Tara
Rabea
Rajib
Rojina
Ripon
Lota
O/L
O/L
O/L
P/M
O/L
F/L
F/L
F/L
F/L
O/L
O/L
F/L
F/L
O/L
O/L
O/L
F/L
F/L
P/M
P/M
F/L
F/L
F/L
P/M
151
206
221
192
192
124
151
180
124
60
69
99
115
58
65
55
102
115
102
131
81
107
180
320
23
17
16
18
18
28
23
19
28
58
49
35
30
59
55
65
34
30
34
26
42
32
19
11
19865
20617
20306
20827
20640
22037
20616
22038
19044
20145
20839
5037
20928
19509
19486
9384
20698
18289
22060
19874
21013
3361
20998
19871
18,20,20
14,15,13
12,13,13
13,15,17
15,15,14
24,23,23
18,20,19
16,15,16
22,22,25
49,50,46
39,40,44
31,28,27
24,25,25
50,48,49
45,45,47
53,55,55
31,26,28
24,25,25
27,27,29
21,24,21
35,38,31
27,27,28
15,15,17
10,8,10
29-03-2013
SL
Operation Name
Operator Name & ID
M/C
type
Actual
output per
hour
Process time Avg. time

(3pcs)
Avg. time with
20%
allowance
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Shoulder join-1
Shoulder join-2
Neck rib edge joint
Neck joint
Sleeve joint-1
Sleeve joint-2
Side seam-1
Side seam-2
Side seam-3
Sleeve hem-1
Sleeve hem-2
Body hem
Label make
Kajoil
Rehena
Reema
Sima
Any
Salma
Rina
Bulbuli
Laboni
Amena
Asadul
Anwara
Johir
Reena
Nupur
Khadija
Mannan
Nargis
Tara
Rabea
Rajib
Rojina
Ripon
Lota
O/L
O/L
O/L
P/M
O/L
F/L
F/L
F/L
F/L
O/L
O/L
F/L
F/L
O/L
O/L
O/L
F/L
F/L
P/M
P/M
F/L
F/L
F/L
P/M
137
192
221
221
206
131
151
192
137
60
68
107
110
58
56
55
99
115
107
124
93
99
160
320
19,20,24
17,13,15
12,14,14
13,13,12
15,14,13
22,21,24
19,20,19
17,15,14
23,20,19
47,47,48
40,42,43
28,28,26
27,25,25
46,51,50
49,52,53
50,53,54
29,30,27
23,27,25
28,26,26
22,24,23
30,31,31
28,29,29
16,18,19
9,10,9
19865
20617
20306
20827
20640
22037
20616
22038
19044
20145
20839
5037
20928
19509
19486
9384
20698
18289
22060
19874
21013
3361
20998
19871
25
18
16
16
17
26
23
18
25
55
50
32
31
59
61
62
35
30
32
28
37
35
22
11

Style no: 29694
Shirt
Date: 27-03-20013
Buyer: Collins
Description: TType: Basic
27-03-2013
SL
Operation Name
Operator Name & ID
M/C
type
Actual
output per
hour

(3pcs)
Avg. time with
20%
allowance
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Shoulder join-1
Shoulder join-2
Neck rib edge joint
Neck joint
Sleeve joint-1
Sleeve joint-2
Side seam-1
Side seam-2
Side seam-3
Sleeve hem-1
Sleeve hem-2
Body hem
Label make
Kohinur
Soriful
Moli
Popi
Sadia
Sahara
Helena
Kobir
Aklima
Asha
Motin
Rojina
Helena
Rahima
Sopna
Najmul
Panna
Rojina
Rina
Samad
Manik
Sahid
Joynal
Moyna
O/L
O/L
O/L
P/M
O/L
F/L
F/L
F/L
F/L
O/L
O/L
F/L
F/L
O/L
O/L
O/L
F/L
F/L
P/M
P/M
F/L
F/L
F/L
P/M
110
180
164
192
180
125
164
164
96
62
70
115
131
58
66
58
125
115
99
137
76
82
180
240
29,26,23
15,19,18
20,17,18
14,13,17
16,15,19
25,21,23
16,20,17
20,16,17
31,29,30
53,42,46
38,42,43
23,25,28
23,20,23
53,48,50
42,46,44
48,52,50
20,27,23
23,25,27
31,26,29
23,20,20
37,38,40
36,33,35
14,19,15
11,11,13
9497
18066
20524
13051
19905
18461
21050
21093
20118
1545
12080
20659
20952
20416
9898
20173
7207
19031
20535
21075
5183
20658
19341
21057
31
20
22
18
20
28
22
22
36
55
49
30
26
60
53
60
28
30
35
25
46
42
19
14
28-03-2013
SL
Operation Name
Operator Name & ID
M/C
type
Actual
output per
hour

(3pcs)
Avg. time with
20%
allowance
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Shoulder join-1
Shoulder join-2
Neck rib edge joint
Neck joint
Sleeve joint-1
Sleeve joint-2
Side seam-1
Side seam-2
Side seam-3
Sleeve hem-1
Sleeve hem-2
Body hem
Label make
Kohinur
Soriful
Moli
Popi
Sadia
Sahara
Helena
Kobir
Aklima
Asha
Motin
Rojina
Helena
Rahima
Sopna
Najmul
Panna
Rojina
Rina
Samad
Manik
Sahid
Joynal
Moyna
O/L
O/L
O/L
P/M
O/L
F/L
F/L
F/L
F/L
O/L
O/L
F/L
F/L
O/L
O/L
O/L
F/L
F/L
P/M
P/M
F/L
F/L
F/L
P/M
125
192
180
222
192
115
164
180
120
66
74
102
131
55
66
58
125
115
160
144
90
93
180
320
26,20,23
16,14,16
19,17,16
11,15,13
16,14,17
23,25,26
19,17,20
17,15,19
28,23,22
46,41,45
38,40,40
29,27,28
21,23,22
52,50,55
43,42,47
50,48,52
23,25,21
26,21,27
29,31,30
19,17,24
34,28,33
33,29,31
15,17,15
9,8,10
9497
18066
20524
13051
19905
18461
21050
21093
20118
1545
12080
20659
20952
20416
9898
20173
7207
19031
20535
21075
5183
20658
19341
21057
28
18
20
16
18
30
22
20
29
53
47
34
26
62
53
60
28
30
36
24
38
37
19
11
29-03-2013
SL
Operation Name
Operator Name & ID
M/C
type
Actual
output per
hour

(3pcs)
Avg. time with
20%
allowance
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Shoulder join-1
Shoulder join-2
Neck rib edge joint
Neck joint
Sleeve joint-1
Sleeve joint-2
Side seam-1
Side seam-2
Side seam-3
Sleeve hem-1
Sleeve hem-2
Body hem
Label make
Kohinur
Soriful
Moli
Popi
Sadia
Sahara
Helena
Kobir
Aklima
Asha
Motin
Rojina
Helena
Rahima
Sopna
Najmul
Panna
Rojina
Rina
Samad
Manik
Sahid
Joynal
Moyna
O/L
O/L
O/L
P/M
O/L
F/L
F/L
F/L
F/L
O/L
O/L
F/L
F/L
O/L
O/L
O/L
F/L
F/L
P/M
P/M
F/L
F/L
F/L
P/M
120
189
164
192
180
120
151
180
125
54
74
110
137
60
70
58
115
106
88
137
93
93
180
240
23,26,22
18,20,20
19,17,17
14,15,17
17,19,15
22,23,26
21,19,17
15,17,15
28,22,20
56,51,55
40,38,39
20,23,28
20,21,23
48,50,47
41,43,40
52,48,48
24,25,25
29,23,30
34,35,31
24,19,20
31,30,33
30,32,32
17,15,19
11,13,11
9497
18066
20524
13051
19905
18461
21050
21093
20118
1545
12080
20659
20952
20416
9898
20173
7207
19031
20535
21075
5183
20658
19341
21057
29
19
22
18
20
29
23
19
28
65
47
31
25
58
49
59
30
32
40
25
37
37
20
14
Data Analysis
Capacity check sheet U-1

(Line: 2)
27-03-2013
SL
Operation Name

type
Actual
Process
output per time
hour
(3pcs)
Avg. time
with 20%
allowance
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
Shoulder join-1
Shoulder join-2
Neck rib edge joint
Neck joint
Sleeve joint-1
Sleeve joint-2
Side seam-1
Side seam-2
Side seam-3
Sleeve hem-1
Sleeve hem-2
Roman
Tuni
Johura
Mukul
Sajida
Taslima
Arif
Rekha
Alal
Hasina
Shapla
Helena
Afsana
Laboni
Ashiq
Parvin
Mukta
Alpona
Khaleda
Hameed
Sayeed
Hasan
138
212
200
225
212
120
157
189
124
68
72
116
113
65
68
72
116
129
106
116
113
103
26
17
18
16
17
30
23
19
29
53
50
31
32
55
53
50
31
28
34
31
32
35
17371
19021
20568
20918
3357
2199
19799
20954
3011
850
19930
18332
20922
20145
19659
3360
2124
19564
20878
7495
20871
20414
O/L
O/L
O/L
P/M
O/L
F/L
F/L
F/L
F/L
O/L
O/L
F/L
F/L
O/L
O/L
O/L
F/L
F/L
P/M
P/M
F/L
F/L
22,24,21
16,13,14
16,14,16
14,12,12
15,13,14
26,23,25
18,20,18
16,15,17
24,25,24
44,46,43
42,40,43
28,26,23
26,29,27
48,44,45
44,42,45
41,42,44
27,25,26
23,24,22
28,30,27
24,25,23
25,28,28
30,28,29
28-03-2013
SL
Operation Name
Operator Name & ID
M/C
type
Actual
output per
hour
Process
time
(3pcs)
Avg. time
with 20%
allowance
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Shoulder join-1
Shoulder join-2
Neck rib edge joint
Neck joint
Sleeve joint-1
Sleeve joint-2
Side seam-1
Side seam-2
Side seam-3
Sleeve hem-1
Sleeve hem-2
Body hem
Label make
Roman
Tuni
Johura
Mukul
Sajida
Taslima
Arif
Rekha
Alal
Hasina
Shapla
Helena
Afsana
Laboni
Ashiq
Parvin
Mukta
Alpona
Khaleda
Hameed
Sayeed
Hasan
Julhash
Sanjida
O/L
O/L
O/L
P/M
O/L
F/L
F/L
F/L
F/L
O/L
O/L
F/L
F/L
O/L
O/L
O/L
F/L
F/L
P/M
P/M
F/L
F/L
F/L
P/M
144
200
180
257
200
129
138
189
144
67
73
120
116
62
69
68
120
129
113
129
113
100
200
257
21,22,20
14,16,14
17,15,18
11,14,12
15,14,16
24,23,21
21,24,22
18,15,16
20,22,21
44,44,46
41,42,40
27,24,25
26,27,26
47,48,50
44,42,43
46,44,42
27,23,26
22,25,23
30,25,25
24,22,23
28,26,27
30,29,30
16,14,16
11,12,12
25
18
20
14
18
28
26
19
25
54
49
30
31
58
52
53
30
28
32
28
32
36
18
14
17371
19021
20568
20918
3357
2199
19799
20954
3011
850
19930
18332
20922
20145
19659
3360
2124
19564
20878
7495
20871
20414
19927
20011
SL
Operation Name
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Shoulder join-1
Shoulder join-2
Neck rib edge joint
Neck joint
Sleeve joint-1
Sleeve joint-2
Side seam-1
Side seam-2
Side seam-3
Sleeve hem-1
Sleeve hem-2
Body hem
Label make
29-03-2013
Operator Name & ID
M/C
type
Actual
output per
hour
Process time Avg. time with

(3pcs)
20%
allowance
Roman
Tuni
Johura
Mukul
Sajida
Taslima
Arif
Rekha
Alal
Hasina
Shapla
Helena
Afsana
Laboni
Ashiq
Parvin
Mukta
Alpona
Khaleda
Hameed
Sayeed
Hasan
Julhash
Sanjida
O/L
O/L
O/L
P/M
O/L
F/L
F/L
F/L
F/L
O/L
O/L
F/L
F/L
O/L
O/L
O/L
F/L
F/L
P/M
P/M
F/L
F/L
F/L
P/M
129
200
200
225
225
133
144
200
144
67
73
124
116
64
67
65
116
124
106
124
100
100
189
277
21,23,24
13,14,17
15,13,18
12,13,13
14,12,13
25,20,22
19,23,21
17,14,15
23,21,20
45,42,47
41,43,40
27,23,22
28,24,26
47,49,45
43,46,45
44,46,47
28,27,24
25,22,24
29,26,28
24,23,24
27,33,29
29,31,29
17,15,15
10,12,10
17371
19021
20568
20918
3357
2199
19799
20954
3011
850
19930
18332
20922
20145
19659
3360
2124
19564
20878
7495
20871
20414
19927
20011
28
18
18
16
16
27
25
18
25
54
49
29
31
56
54
55
31
29
34
29
36
36
19
13

(Line: 3)
27-03-2013
SL
Operation Name

type
Actual
Process
output per time
hour
(3pcs)
Avg. time
with 20%
allowance
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
Shoulder join-1
Shoulder join-2
Neck rib edge joint
Neck joint
Sleeve joint-1
Sleeve joint-2
Side seam-1
Side seam-2
Side seam-3
Sleeve hem-1
Sleeve hem-2
Kajoil
Rehena
Reema
Sima
Any
Salma
Rina
Bulbuli
Laboni
Amena
Asadul
Anwara
Johir
Reena
Nupur
Khadija
Mannan
Nargis
Tara
Rabea
Rajib
Rojina
131
180
192
206
180
120
131
180
137
58
68
103
107
55
56
56
102
120
102
115
93
96
26
19
18
17
19
29
26
20
25
60
50
34
32
62
61
61
34
29
34
30
37
36
19865
20617
20306
20827
20640
22037
20616
22038
19044
20145
20839
5037
20928
19509
19486
9384
20698
18289
22060
19874
21013
3361
O/L
O/L
O/L
P/M
O/L
F/L
F/L
F/L
F/L
O/L
O/L
F/L
F/L
O/L
O/L
O/L
F/L
F/L
P/M
P/M
F/L
F/L
21,21,23
14,16,17
13,14,17
13,14,15
15,17,17
23,24,25
20,21,26
17,17,16
25,20,19
50,51,49
43,40,44
30,27,28
24,29,29
53,54,48
50,53,49
51,51,52
28,28,29
24,24,25
28,29,26
23,24,29
30,33,31
29,30,30
28-03-2013
SL
Operation Name
Operator Name & ID
M/C
type
Actual
output per
hour
Process
time
(3pcs)
Avg. time
Avg. time with
20%
allowance
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Shoulder join-1
Shoulder join-2
Neck rib edge joint
Neck joint
Sleeve joint-1
Sleeve joint-2
Side seam-1
Side seam-2
Side seam-3
Sleeve hem-1
Sleeve hem-2
Body hem
Label make
Kajoil
Rehena
Reema
Sima
Any
Salma
Rina
Bulbuli
Laboni
Amena
Asadul
Anwara
Johir
Reena
Nupur
Khadija
Mannan
Nargis
Tara
Rabea
Rajib
Rojina
Ripon
Lota
O/L
O/L
O/L
P/M
O/L
F/L
F/L
F/L
F/L
O/L
O/L
F/L
F/L
O/L
O/L
O/L
F/L
F/L
P/M
P/M
F/L
F/L
F/L
P/M
151
206
221
192
192
124
151
180
124
60
69
99
115
58
65
55
102
115
102
131
81
107
180
320
18,20,20
14,15,13
12,13,13
13,15,17
15,15,14
24,23,23
18,20,19
16,15,16
22,22,25
49,50,46
39,40,44
31,28,27
24,25,25
50,48,49
45,45,47
53,55,55
31,26,28
24,25,25
27,27,29
21,24,21
35,38,31
27,27,28
15,15,17
10,8,10
23
17
16
18
18
28
23
19
28
58
49
35
30
59
55
65
34
30
34
26
42
32
19
11
19865
20617
20306
20827
20640
22037
20616
22038
19044
20145
20839
5037
20928
19509
19486
9384
20698
18289
22060
19874
21013
3361
20998
19871
29-03-2013
SL
Operation Name
Operator Name & ID
M/C
type
Actual
output per
hour

(3pcs)
Avg. time with
20%
allowance
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Shoulder join-1
Shoulder join-2
Neck rib edge joint
Neck joint
Sleeve joint-1
Sleeve joint-2
Side seam-1
Side seam-2
Side seam-3
Sleeve hem-1
Sleeve hem-2
Body hem
Label make
Kajoil
Rehena
Reema
Sima
Any
Salma
Rina
Bulbuli
Laboni
Amena
Asadul
Anwara
Johir
Reena
Nupur
Khadija
Mannan
Nargis
Tara
Rabea
Rajib
Rojina
Ripon
Lota
O/L
O/L
O/L
P/M
O/L
F/L
F/L
F/L
F/L
O/L
O/L
F/L
F/L
O/L
O/L
O/L
F/L
F/L
P/M
P/M
F/L
F/L
F/L
P/M
137
192
221
221
206
131
151
192
137
60
68
107
110
58
56
55
99
115
107
124
93
99
160
320
19,20,24
17,13,15
12,14,14
13,13,12
15,14,13
22,21,24
19,20,19
17,15,14
23,20,19
47,47,48
40,42,43
28,28,26
27,25,25
46,51,50
49,52,53
50,53,54
29,30,27
23,27,25
28,26,26
22,24,23
30,31,31
28,29,29
16,18,19
9,10,9
19865
20617
20306
20827
20640
22037
20616
22038
19044
20145
20839
5037
20928
19509
19486
9384
20698
18289
22060
19874
21013
3361
20998
19871
25
18
16
16
17
26
23
18
25
55
50
32
31
59
61
62
35
30
32
28
37
35
22
11

(Line: 4)
27-03-2013
SL
Operation Name
Operator Name & ID
M/C
type
Actual
output per
hour

(3pcs)
Avg. time with
20%
allowance
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Shoulder join-1
Shoulder join-2
Neck rib edge joint
Neck joint
Sleeve joint-1
Sleeve joint-2
Side seam-1
Side seam-2
Side seam-3
Sleeve hem-1
Sleeve hem-2
Body hem
Label make
Kohinur
Soriful
Moli
Popi
Sadia
Sahara
Helena
Kobir
Aklima
Asha
Motin
Rojina
Helena
Rahima
Sopna
Najmul
Panna
Rojina
Rina
Samad
Manik
Sahid
Joynal
Moyna
O/L
O/L
O/L
P/M
O/L
F/L
F/L
F/L
F/L
O/L
O/L
F/L
F/L
O/L
O/L
O/L
F/L
F/L
P/M
P/M
F/L
F/L
F/L
P/M
110
180
164
192
180
125
164
164
96
62
70
115
131
58
66
58
125
115
99
137
76
82
180
240
29,26,23
15,19,18
20,17,18
14,13,17
16,15,19
25,21,23
16,20,17
20,16,17
31,29,30
53,42,46
38,42,43
23,25,28
23,20,23
53,48,50
42,46,44
48,52,50
20,27,23
23,25,27
31,26,29
23,20,20
37,38,40
36,33,35
14,19,15
11,11,13
9497
18066
20524
13051
19905
18461
21050
21093
20118
1545
12080
20659
20952
20416
9898
20173
7207
19031
20535
21075
5183
20658
19341
21057
31
20
22
18
20
28
22
22
36
55
49
30
26
60
53
60
28
30
35
25
46
42
19
14
28-03-2013
SL
Operation Name
Operator Name & ID
M/C
type
Actual
output per
hour

(3pcs)
Avg. time with
20%
allowance
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Shoulder join-1
Shoulder join-2
Neck rib edge joint
Neck joint
Sleeve joint-1
Sleeve joint-2
Side seam-1
Side seam-2
Side seam-3
Sleeve hem-1
Sleeve hem-2
Body hem
Label make
Kohinur
Soriful
Moli
Popi
Sadia
Sahara
Helena
Kobir
Aklima
Asha
Motin
Rojina
Helena
Rahima
Sopna
Najmul
Panna
Rojina
Rina
Samad
Manik
Sahid
Joynal
Moyna
O/L
O/L
O/L
P/M
O/L
F/L
F/L
F/L
F/L
O/L
O/L
F/L
F/L
O/L
O/L
O/L
F/L
F/L
P/M
P/M
F/L
F/L
F/L
P/M
125
192
180
222
192
115
164
180
120
66
74
102
031
55
66
58
125
115
160
144
90
93
180
320
26,20,23
16,14,16
19,17,16
11,15,13
16,14,17
23,25,26
19,17,20
17,15,19
28,23,22
46,41,45
38,40,40
29,27,28
21,23,22
52,50,55
43,42,47
50,48,52
23,25,21
26,21,27
29,31,30
19,17,24
34,28,33
33,29,31
15,17,15
9,8,10
9497
18066
20524
13051
19905
18461
21050
21093
20118
1545
12080
20659
20952
20416
9898
20173
7207
19031
20535
21075
5183
20658
19341
21057
28
18
20
16
18
30
22
20
29
53
47
34
26
62
53
60
28
30
36
24
38
37
19
11
29-03-2013
SL
Operation Name
Operator Name & ID
M/C
type
Actual
output per
hour

(3pcs)
Avg. time with
20%
allowance
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Shoulder join-1
Shoulder join-2
Neck rib edge joint
Neck joint
Sleeve joint-1
Sleeve joint-2
Side seam-1
Side seam-2
Side seam-3
Sleeve hem-1
Sleeve hem-2
Body hem
Label make
Kohinur
Soriful
Moli
Popi
Sadia
Sahara
Helena
Kobir
Aklima
Asha
Motin
Rojina
Helena
Rahima
Sopna
Najmul
Panna
Rojina
Rina
Samad
Manik
Sahid
Joynal
Moyna
O/L
O/L
O/L
P/M
O/L
F/L
F/L
F/L
F/L
O/L
O/L
F/L
F/L
O/L
O/L
O/L
F/L
F/L
P/M
P/M
F/L
F/L
F/L
P/M
120
144
164
192
180
120
151
180
125
54
74
110
137
60
70
58
115
106
88
137
93
93
170
240
23,26,22
18,20,21
19,17,17
14,15,17
17,19,15
22,23,26
21,19,17
15,17,15
28,22,20
56,51,55
40,38,39
20,23,28
20,21,23
48,50,47
41,43,40
52,48,48
24,25,25
29,23,30
34,35,31
24,19,20
31,30,33
30,32,32
17,15,19
11,13,11
9497
18066
20524
13051
19905
18461
21050
21093
20118
1545
12080
20659
20952
20416
9898
20173
7207
19031
20535
21075
5183
20658
19341
21057
29
24
22
18
20
29
23
19
28
65
47
31
25
58
49
59
30
32
40
25
37
37
20
14
Result
For day 1
For day 2
For day 3
After analysis we found the below

result
Day 1
Day 2
Day 3
Conclusion
The contributions and incessant efforts of all the group
members to complete the project report are highly
appreciative. The challenging environment in 21 st century
demands that textile education should be meaningful and
responsive to develop a mechanism to produce dynamic
and technically competitive human resource in order to meet
the challenges of the global world. Right and effective
strategies needs to be adopted for affecting productivity with
quality improvements in textile education thereby making it
relevant and useful not only for the sustained growth and
development of the textile institutes but also in serving the
societies in a progressive way.
http://www.textilelab.blogspot.com (Visit )
My Facebook Textile related Pages

1. Yarn Manufacturing Technology
Link : http://www.facebook.com/pages/Yarn-ManufacturingTechnology/485014954866808
2. Fabric Manufacturing Technology
Link : http://www.facebook.com/pages/Fabric-ManufacturingTechnology/459520217425605
3. Garments Manufacturing Technology
Link : http://www.facebook.com/pages/Garments-ManufacturingTechnology/472364799463126
3. Wet processing Technology
Link : http://www.facebook.com/pages/Wet-Processing-TechnologyDyeing-/468645219825404
4. Fashion-Design-and-Technology
Link : http://www.facebook.com/pages/Fashion-Design-and-

Line Balancing

Transféré par

Informations du document

Description originale:

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

Line Balancing

Transféré par

Droits d'auteur :

Formats disponibles

Prepared By :

Prepared By : Mazadul Hasan sheshir

Department Of Textile Engineering

Total Textile Process at a Glance

LINE BALANCING (Process Organization)

The Line Balancing is to design a smooth production flow

Reasons to have balance the production

How do we start balancing the production

There are 3 rules for balancing

(2) Solve problems before they become any larger

SMV = B.T + Allowances

1.2*50 0.8*75 0.6*100 0.5*125

Get bundle and sort parts

Match pocket flap to lining

Sew round flap

Trim threads and turn out

Top stitch flap

Close bundle and place

Total basic time/garment (brought forward) 1.416

Add personal needs and relaxation allowances 14%

Standard minute Value (SMV) = Basic time + all

= 1.485 + 0.208 = 1.693

Load and capacity

The scheduling rule

Balancing & Capacity

Uncertainty about the

Uncertainty about the

Bottleneck Process Time

Pitch Diagram in the form of Column Graph

How to reduce the number of

= 2 x Pitch Time Upper Limit

Operator Name & ID M/C

Operator Name & ID M/C

Operator Name & ID M/C

One Composite Mills Ltd.

Operator Name & ID M/C

Operator Name & ID

Actual output Process time

Operator Name & ID

Process time Avg. time

One Composite Mills Ltd.

Target: 180pcs/ hour

Operator Name & ID

Process time Avg. time

Operator Name & ID

Process time Avg. time

Operator Name & ID

Process time Avg. time

Capacity check sheet U-1

Operator Name & ID M/C

Operator Name & ID

Process time Avg. time with

Capacity check sheet U-1

Operator Name & ID M/C

Operator Name & ID

Operator Name & ID

Process time Avg. time

Capacity check sheet U-1

Operator Name & ID

Process time Avg. time

Operator Name & ID

Process time Avg. time

Operator Name & ID

1.250 0.875 0.6100 0.5125