Productivity Analysis and Application of Improvement Techniques In a Manufacturing Plant (Ready made Garments Industry)

Abstract

Productivity is an important fact for every manufacturing industry. It is a vital to decrease the production lead time as well as manufacturing cost. For productivity improvement it becomes essential to decrease the waiting time, process bottlenecks and increase the production line efficiency. Time study and line balancing are effective techniques to reduce the operation time and improve the productivity. Assembly line balancing technique was used in some manufacturing industries for single production line to identify and remove the no value added activities and increase the productivity. But, it becomes essential to apply time study and line balancing techniques for the number of production lines of various products in small and large RMG industries to improve its productivity. In this work, a single case study carried out on SK Garments, which is producing T-shirt. The current state of productivity measures in the plant and its effectiveness of the measurement were studied. During study period time study is performed on four different products of RMG industries and production lines are balanced through the distribution of works among the work stations by line balancing. Thus, new production layouts are modeled with the balanced capacity combining both modular line and traditional manufacturing system together. This research report provides pragmatic guidelines for the garments manufacturers to improve their industrial productivity and capacity by applying some essential tools like time study, line balancing etc. This study also suggests the possible improvement techniques that can be applied to improve the productivity of the plant.