JIT Implementation Seweing Line
JIT Implementation Seweing Line
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All content following this page was uploaded by Israt Parveen on 23 August 2023.
Abstract
On time delivery with quality and quantity is important for any manufacturing industry, especially in garment
sectors. At present, in RMG industries, lead time is decreasing day by day and customer requirements also
continuously changing. The primary objective of this study is to identify the defects in sewing sections that
hinders the overall productivity of garments industry in Bangladesh and find out the ways how to reduce those
defects in sewing line by implementing Just-in-Time (JIT) techniques. Three different product lines (Jacket, Polo
shirt, and T-shirt) have been considered to implement this study. The sample respondents were selected from a
reputed textile industry in Bangladesh. Purposive sampling technique is followed by data collection from sewing
section and indication of major problems. After indication, improvement proposal is given to the industry from
which the productivity as well as line efficiency has compared before and after applying the techniques. The
output of the study includes the production capacity, line target, line efficiency, line performance of the respective
sewing section that has been increased far well than before within the time duration of three months. It is also
suggested that, different techniques like process integration, job sharing, multitasking etc. can also be
implemented if responsible authorities of garments industry try to improve the current state situation.
Keywords
Just-in-Time (JIT), Lean manufacturing, Operation layout, Line efficiency, Productivity.
1. Introduction
As the labor wage is increasing in developing countries, the apparel manufacturing has been migrating from the
high wage developed country to low wage developing countries. Even the labor cost is cheaper than in developed
countries due to the specific market nature of the garment industries. For example, the short production of life
cycle, high volatility, low predictability, high level of impulse purchase, the quick market response: garment
industries are facing the greatest challenges these days (Lucy Daly and Towers, 2004).
Nowadays industries are getting more volumes (orders), but number of styles they have to handle has increased
drastically. In recent day, due to small order quantities and complex designs, the garments industry has to produce
multiple styles even within a day; this needs higher flexibility in volume and style change over.
In Bangladesh industries have been running in a traditional way for years and rigid to change. Industry owners are
happy as long as the business is sustainable. Now the time has come to struggle with global market in garment
industries if the owners want to run it further. The best way to cope with all these challenges is the
implementation of lean manufacturing. Its implementation has contributed to the success of many organizations
and is used by companies worldwide. JIT is an all-encompassing philosophy that is founded on the concept of
eliminating waste. The word waste might make one think of garbage, or paper, or inventory. The broad view of
JIT is now often termed lean production or lean systems. If this concept is properly maintained, they will serve the
purpose of flexibility and save a lot of money by reducing production lead time, reducing inventory, increasing
productivity, training operators multiple works and by rework.
2. Methodology
It is a management idea that attempts to eliminate sources of manufacturing waste by producing the right part in
the right place at the right. In the manufacturing process size of batches are related to potential errors in
part/production, i.e., smaller batches such as used in JIT systems will potentially reduce the average error per
part/production population.
2.3 JIT Purchasing: The Idea of JITP runs counter to the traditional purchasing practices where materials are
brought well in advance before their use. Under this, the supplier selection, product development and production
lot sizing become very critical. Implementation of JIT in sewing line basically explains (a) Reduction of waste of
motion; (b) Reduction of waste in waiting time; (c) Reduction of waste of inventory; (d) Reduction of waste of
defects
AVG.
Time
Cycle Time (in sec) AVG.
Sl Operation M/C AVG.Time with Capacity
Time Rating% SMV
No Description Name (Min) 15% /Hour
(Sec)
allowanc
1 2 3 4 5 e
1 Label Making SN 11 12 17 13 13 13 0.22 0.253 80% 0.2 300
Back Side Label
2 SN 12 17 16 11 13 14 0.23 0.2645 80% 0.21 286
Join at Moon
3 Moon Join SN 16 15 15 14 15 15 0.25 0.2875 80% 0.23 261
4 Placket Join SN 16 17 18 17 14 16 0.27 0.3105 80% 0.25 240
5 Nose Tack SN 11 13 12 11 12 12 0.2 0.23 80% 0.18 333
6 Shoulder Join O/L 18 17 21 16 19 18 0.3 0.345 80% 0.28 214
7 Collar Servicing O/L 4 4 3 4 6 4 0.07 0.0805 80% 0.06 1000
8 Collar Tack SN 14 15 14 13 14 14 0.23 0.2645 80% 0.21 286
9 Collar Join O/L 13 16 17 16 14 15 0.25 0.2875 80% 0.23 261
10 Collar Piping PIPING 10 12 12 13 16 13 0.22 0.253 80% 0.2 300
Placket Kacha
11 SN 23 17 15 15 17 17 0.28 0.322 80% 0.26 231
Topstitch
12 Placket 1/16 SN 13 16 19 17 18 17 0.28 0.322 80% 0.26 231
Back Neck Tape
13 SN 15 13 16 14 13 14 0.23 0.2645 80% 0.2 300
Topstitch
14 Placket Box SN 15 17 15 17 16 16 0.27 0.3105 80% 0.25 240
15 Sleeve Hem F/L 7 7 8 9 8 8 0.13 0.1495 80% 0.12 500
Sleeve Match &
16 Shoulder H 21 16 23 19 21 20 0.33 0.3795 80% 0.3 200
Scissoring
17 Sleeve Join O/L 23 23 30 33 30 28 0.47 0.5405 80% 0.43 140
18 Side Join O/L 33 38 39 42 36 38 0.63 0.7245 80% 0.58 103
19 Chap Tack SN 20 21 23 18 22 21 0.35 0.4025 80% 0.32 188
20 Placket End Tack SN 15 17 20 23 14 18 0.3 0.345 80% 0.28 214
21 Bottom Hem F/L 10 13 14 15 16 14 0.23 0.2645 80% 0.21 286
Button
22 Button Hole 15 14 15 17 17 16 0.27 0.3105 80% 0.25 240
Hole
Button
23 Button Attach 15 18 21 20 20 19 0.32 0.368 80% 0.29 207
Attach
24 Thread Cutting H 25 20 20 18 21 21 0.35 0.4025 80% 0.32 186
25 Button Close H 10 8 12 13 14 11 0.19 0.2185 80% 0.17 353
6.29
After implementing layout plan & data
AVG.
Cycle Time (in sec) AVG.
Sl Operation AVG.Time Time with Ratin Capacity
M/C Name Time SMV
No Description (Min) 15% g% /Hour
(Sec)
allowance
1 2 3 4 5
1 Label Making SN 12 10 11 12 11 11 0.18 0.207 80% 0.17 353
Back Side Label
2 SN 13 15 11 12 14 13 0.22 0.253 80% 0.2 300
Join at Moon
3 Moon Join SN 14 11 15 11 12 13 0.22 0.253 80% 0.2 300
4 Placket Join SN 17 15 14 16 13 15 0.25 0.2875 80% 0.23 261
5 Nose Tack SN 10 12 11 10 11 11 0.18 0.207 80% 0.17 353
6 Shoulder Join O/L 16 14 17 14 15 15 0.25 0.2875 80% 0.23 261
7 Collar Servicing O/L 5 4 3 3 4 4 0.07 0.0805 80% 0.06 1000
8 Collar Tack SN 14 12 11 13 12 12 0.2 0.23 80% 0.18 333
9 Collar Join O/L 13 14 16 14 13 14 0.23 0.2645 80% 0.21 286
10 Collar Piping PIPING 10 12 11 13 12 12 0.2 0.23 80% 0.18 333
Placket Kacha
11 SN 21 16 14 15 15 16 0.27 0.3105 80% 0.25 240
Topstitch
12 Placket 1/16 SN 13 16 15 14 18 15 0.25 0.2875 80% 0.3 200
Back Neck Tape
13 SN 14 15 12 13 12 13 0.22 0.253 80% 0.2 300
Topstitch
14 Placket Box SN 15 14 16 15 14 15 0.25 0.2875 80% 0.23 261
15 Sleeve Hem F/L 7 7 6 8 7 7 0.12 0.138 80% 0.11 545
Sleeve Match &
16 Shoulder H 18 15 17 15 16 16 0.27 0.3105 80% 0.25 240
Scissoring
17 Sleeve Join O/L 25 24 23 23 24 24 0.4 0.46 80% 0.37 162
18 Side Join O/L 33 32 31 32 32 32 0.53 0.6095 80% 0.49 122
19 Chap Tack SN 20 19 21 18 22 20 0.33 0.3795 80% 0.3 200
20 Placket End Tack SN 15 18 15 16 16 16 0.27 0.3105 80% 0.25 240
21 Bottom Hem F/L 11 13 14 13 15 13 0.22 0.253 80% 0.2 300
22 Button Hole Button Hole 15 14 15 16 16 15 0.25 0.2875 80% 0.23 261
Button
23 Button Attach 17 18 20 17 18 18 0.3 0.345 80% 0.28 214
Attach
24 Thread Cutting H 22 20 18 19 21 20 0.33 0.3795 80% 0.3 200
25 Button Close H 11 10 8 9 12 10 0.17 0.1955 80% 0.16 375
5.75
SMV calculation is used for determining workers efficiency, line capacity of a factory unit. It can determine the
efficiency of production line, production cost. What should be the production target for the specific operation &
for the production line of a specific style can also be measured by using SMV.
After calculation, Production capacity per shift 1168 pcs and after JIT implementation production capacity per
shift is 1280 Pcs and production per shift increased by 112 Pcs.
= 176 Pcs
Before JIT implementation the line target was 1912 Pcs and after JIT implementation the line target become 2088
pcs. Line target per shift increases by 176 Pcs.
Before JIT implementation the Line efficiency per hour was 61.22% and after JIT implementation the line
efficiency become 61.33 %. Line efficiency per hour increased by 0.11%.
Before JIT implementation Line Performance was 61.09% and after JIT implementation Line Performance
become 61.30%. The increased Line Performance per hour was 0.21%.
The standard minute value (SMV) is a visualization tool and its goal is to identify, demonstrate and elimination of
waste in the process. Before eliminating waste, we must be able to see it. SMV can serve as a starting point to
help management, engineers, production associates, schedulers, suppliers, and customers, recognize waste and
identify its causes. Before implementation of tools & techniques of JIT training were provided to the people
specially supervisor and make them knowledgeable about different types of waste and how to identify waste also
reduce waste. Operator also trained on kaizen how small change make work simple and improve visibility of off-
standards and they were introduced to changing for better.
In current state assessment it was found that Production Capacity per shift (in pcs) is 1168, line efficiency 61.22%
which shows huge opportunities for improvement in those areas. It has started with 5 pieces bundling system in
sewing section and then following up the line regularly and capacity study from time to time. After
implementation of team work, process integration, job sharing, multi machine operating and balancing the task,
eliminating unnecessary activities, team has achieved 61.33%-line efficiency, Production capacity per shift (in
pcs) 1280. Besides defects, WIP, transportation also reduced than previous traditional systems.
The study was done with a limited scope as there were limited time and restriction of permission from industrial
authority during research work .As industry always go for profit, desired production line allocation were also quite
difficult for collecting data. Future work may include super market pull between cuttings and sewing section .Also
implementation of SMV and Kanban system to keep WIP at minimum level. The future work may include helper
less zero defect line where each operator will be the quality at the source and creation of standard operating
procedure (SOP) for each sections and for incentive policy also.
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Biographies
Israt Parveen is continuing her M.Sc. in Textile Engineering study in the Department of Textile Engineering at
Mawlana Bhashani Science and Technology University. She earned her B.Sc. in Textile Engineering degree from
the same university in 2016 and secured the first position in her class. She has published number of journal papers
and participated in conferences.
Md. Arif Mia earned his B.Sc. in Textile Engineering from the Department of Textile Engineering of Mawlana
Bhashani Science and Technology University in 2017. He is working as a Management Trainee in Southeast
Limited, Tangail, Bangladesh.
Md. Sujan Ali earned his B.sc in Textile Engineering in the Department from the Department of Textile
Engineering of Mawlana Bhashani Science and Technology University in 2017.
Khandoker Rafsun-Ul-Hasan earned his B.sc in Textile Engineering in the Department from the Department of
Textile Engineering of Mawlana Bhashani Science and Technology University in 2017.
Md. Moshiur Rahman earned his B.sc in Textile Engineering in the Department from the Department of Textile
Engineering of Mawlana Bhashani Science and Technology University in 2017.
Professor Dr. Md. Iqbal Mahmud is working in the Department of Textile Engineering at Mawlana Bhashani
Science and Technology (MBSTU), Bangladesh. He received his B.Sc. (2002), M.Sc. (2010) and Ph.D. (2015)
degree in Mechanical Engineering from Islamic University of Technology (IUT), Bangladesh and Kongju
National University (KNU), South Korea respectively. He has published number of research articles in reputed
journal and participated in national and international conferences. His teaching and research activities have been
focusing on Mechanical Engineering, Industrial Engineering, Renewable Energy, Ergonomics, and Operations
Management.
Professor Dr. Haeng Muk Cho is a Professor of Mechanical Engineering and System Design in the division of
Mechanical and Automotive Engineering at Kongju National University (KNU), South Korea. His teaching and
research activities have been focusing on Internal Combustion Engines, Car Alternative Fuel, Biodiesel, Car
Emission Control, Hybrid Vehicles etc.