project work presentation
TRANSCRIPT
WELCOME TO MY PROJECT WORK PRESENTATION
PRESENTED BY:MD. SHAIF UDDIN
DEPARTMENT OF LEATHER PRODUCTS ENGINEERING
EXAM ROLL: 118REGISTRATION NO:3466
ILET,DU
TITLE OF MY PROJECT WORK
STUDIES ON THE IMPROVEMENT OF
PRODUCTIVITY THROUGH REDUCTION OF WORK CONTENT IN CLOSING
DEPARTMENT
AIMS OF THE PROJECT•Reducing work content.•Productivity Improvement.• Better utilization of manpower, material, plant and equipment.•Improved working method.•Reducing ineffective time.•Increasing efficiency.
Design of the product
Front View
Back View
1. Cutting all leather, lining & reinforcement materials
2. Splitting
3. Skiving
4. Inspection & Numbering
5. Marking
6. Edge coloring & Buffing
7. Zipper Cutting
8. Stamping/ Embossing
9. Gluing on leather, PVC, Rabose & EVA attaching on leather
10. Two pieces of front & back part leather stitching face to face with single and double needle flat bed
sewing machine & hammering and threads trimming.
Flow Diagram of Sequential
Operations
11. Foam attaching to front & back part leather by applying adhesive
12. Folding top edge of front part
13. Folding the top edge of back part keeping two sides raw edge
14. Attaching #5 no. metal zipper with runner on top edge of back part by applying adhesive
15. Attaching one edge of back zipper pocket lining on lower edge of zipper with folded top
edge of back part by applying adhesive
16. Stitching top edge of back part with zipper and one edge of back zipper pocket lining & thread
trimming
17. Folding two sides of back top Patti & hammering
18. Attaching back top Patti with zipper and raw edge of back part by applying adhesive
19. Attaching another edge of back zipper pocket lining on top edge of zipper with folded back top
Patti by applying adhesive
20. Stitching back top Patti with zipper , raw edge of back part and another edge of zipper pocket
lining & thread trimming
21. Stitching two opened edge of back zipper pocket lining & thread trimming
22. Attaching EVA with two gusset
23. Folding top edge of two gusset & hammering
24. Gluing on two parts of ring loop and attaching with hammering
25. Stitching ring loop with square ring at marking position on gusset & threads trimming
26. Belt folding 6mm from edge with glue
27. Attaching both part of belt & hammering
28. Belt stitching 2.5 mm from edge & threads trimming
29. Attaching rabose with bottom
30. Folding two edge of bottom & hammering
31. Attaching two gusset with bottom by applying adhesive
32. Stitching two gusset with bottom & thread trimming
33. Stitching front & back part with stitched gusset and bottom part & thread trimming
34. Square ring, belt loop & buckle fitting with belt
35. Stitching belt with gusset of bag & threads trimming
36. Attaching foam with flap upper by applying adhesive
37. Attaching PVC on the attached foam of flap upper by applying adhesive
38. Folding the round of flap upper & hammering
39. Attaching EVA sheet with two counter flap side strap
40. Folding two counter flap side strap & hammering
41. Attaching two counter flap side strap with counter flap by applying adhesive
42. Stitching two counter flap side strap with counter flap & thread trimming
43. Attaching EVA with counter flap bottom strap
44. Folding counter flap bottom strap & hammering
45. Attaching counter flap bottom strap with counter flap by applying adhesive
46. Stitching counter flap bottom strap with counter flap & thread trimming
47. Attaching flap upper & counter flap by applying adhesive
48. Stitching flap upper & counter flap with double needle sewing machine & thread trimming
49. Fixing top part of magnet on the flap
50. Stitching flap with back top Patti by double needle sewing machine & thread trimming
51. Fixing bottom part of magnet on front part of bag
52. Preparation of Handy pocket
53. Stitching Handy pocket with front part inner lining & threads trimming
60. Double face adhesive tape applying on the edge of inner lining & folding
59. Stitching two inner gusset lining with front and back part inner lining & threads trimming
58. Stitching two sides of inner zipper pocket lining & threads trimming
57. Stitching inner zipper pocket lining with 3 No. nylon zipper & threads trimming
56. Attaching inner zipper pocket lining with 3 No. nylon zipper
55. Attaching #3 no. nylon zipper with runner & puller at folded zipper portion of back part inner
lining
54. Folding four edges of zipper cut portion of back part inner lining
64. Puller edge stitching 2.5mm around & threads trimming
63. Puller edge folding with glue
62. Inner lining stitching with body 2.5mm top edge & threads trimming
61. Edge of folded inner lining attached with the edge of bag body
65. Puller setting with zipper runner by fitting o-ring of metal zipper
66. Final stitch inspection
67. Cleaning and dressing
68. Stuffing
69. Inserting Bur code, Internet level, Price tag & safety label
70. Final checking and finishing
71. Packing of Bag
Work content Work content means the amount of work "Contained in" a given product or process measured in man-hour or machine hour. The basic work content is the time the product would take to manufacture on the operation to perform, if the design or specification was perfect, if the process of method of manufacture or operation was perfectly carried out, and if there was no loss of working time from any cause whatever during the period of the operation.
The basic work content is the irreducible minimum time theoretically required to produce one unit of output.
Total Work Content = Basic Work Content + Added Work Content
PRODUCTIVITY A general definition of productivity is the relationship between the output generated by production and the input provided to create this output.
Out putProductivity = ----------------- In put
From the definition of productivity, it is apparent that a higher total productivity may result, if-
• More output is produced with the same on lesser input.• The Same output is produced with lesser input, and• More output is produced with more input; the proportional increase in output being more that the increase in input.
PRODUCTIVITY IMPROVEMENT TECHNIQUES
I. Technology basedII. Employee basedIII. Product basedIV. Task basedV. Material based
WORK STUDY
WORK MEASUREMENTWork Measurement is the application of techniques designed to establish the time for a qualified worker to carry out a specific job at a defined Level of performance.
Work Measurement techniqueTime study.Synthesis.Predetermined Motion Time System (PMTS).Analytical Estimate.Work Sampling.
TIME STUDYThe time study is a work measurement technique for
recording times and rates of working for the elements of a specified job carried out under specified conditions, and for analyzing the data so as to obtain the time necessary for
carrying out job at a defined level of performance
Basic Time Study Equipment StopwatchA study boardTime study formSmall calculatorMeasuring instruments such as a measuring tape, steel rule, spring balance etc.
Critical Examination: (Basic Analysis)Every activity should be subjected to the following question asked one after the other in their proper sequence. The answers of these questions wilt from the basis for the development of the improved method: 1.Purpose?2. Place?3. Sequence?4.Person?5.Method?
Cutting all leather, lining & reinforcement materialsSplitting
SkivingInspection & Numbering
MarkingEdge coloring & Buffing
Zipper CuttingStamping/ Embossing
Gluing on leather, PVC, Rabose & EVA attaching on leatherTwo pieces of front & back part leather stitching face to face with single and double needle flat bed sewing machine & hammering and threads trimming.
Foam attaching to front & back part leather by applying adhesive Folding top edge of front part
Folding the top edge of back part keeping two sides raw edgeAttaching #5 no. metal zipper with runner on top edge of back part by applying adhesive
Attaching one edge of back zipper pocket lining on lower edge of zipper with folded top edge of back part by applying adhesiveStitching top edge of back part with zipper and one edge of back zipper pocket lining & thread trimming
Folding two sides of back top Patti & hammeringAttaching back top Patti with zipper and raw edge of back part by applying adhesive
Attaching another edge of back zipper pocket lining on top edge of zipper with folded back top Patti by applying adhesiveStitching back top Patti with zipper , raw edge of back part and another edge of zipper pocket lining & thread trimming
Stitching two opened edge of back zipper pocket lining & thread trimmingAttaching EVA with two gusset
Folding top edge of two gusset & hammeringGluing on two parts of ring loop and attaching with hammering
Stitching ring loop with square ring at marking position on gusset & threads trimmingBelt folding 6mm from edge with glue
Attaching both part of belt & hammeringBelt stitching 2.5 mm from edge & threads trimming
Attaching rabose with bottom Folding two edge of bottom & hammering
Attaching two gusset with bottom by applying adhesiveStitching two gusset with bottom & thread trimming
Stitching front & back part with stitched gusset and bottom part & thread trimmingSquare ring, belt loop & buckle fitting with belt
Stitching belt with gusset of bag & threads trimmingAttaching foam with flap upper by applying adhesive
Attaching PVC on the attached foam of flap upper by applying adhesiveFolding the round of flap upper & hammering
Attaching EVA sheet with two counter flap side strap Folding two counter flap side strap & hammering
Attaching two counter flap side strap with counter flap by applying adhesiveStitching two counter flap side strap with counter flap & thread trimming
Attaching EVA with counter flap bottom strap Folding counter flap bottom strap & hammering
Attaching counter flap bottom strap with counter flap by applying adhesiveStitching counter flap bottom strap with counter flap & thread trimming
Attaching flap upper & counter flap by applying adhesiveStitching flap upper & counter flap with double needle sewing machine & thread trimming
Fixing top part of magnet on the flapStitching flap with back top Patti by double needle sewing machine & thread trimming
Fixing bottom part of magnet on front part of bagPreparation of Handy pocket
Stitching Handy pocket with front part inner lining & threads trimmingFolding four edges of zipper cut portion of back part inner lining
Attaching #3 no. nylon zipper with runner & puller at folded zipper portion of back part inner liningAttaching inner zipper pocket lining with 3 No. nylon zipper
Stitching inner zipper pocket lining with 3 No. nylon zipper & threads trimmingStitching two sides of inner zipper pocket lining & threads trimming
Stitching two inner gusset lining with front and back part inner lining & threads trimmingDouble face adhesive tape applying on the edge of inner lining & folding
Edge of folded inner lining attached with the edge of bag bodyInner lining stitching with body 2.5mm top edge & threads trimming
Puller edge folding with gluePuller edge stitching 2.5mm around & threads trimming
Puller setting with zipper runner by fitting o-ring of metal zipperFinal stitch inspectionCleaning and dressing
StuffingInserting Bur code, Internet level, Price tag & safety label
Final checking and finishingPacking of Bag
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
Cutting all leather, lining & reinforcement materials
Skiving
Marking
Zipper Cutting & Stamping/ Embossing
Two pieces of front & back part leather stitching face to face with single and double needle flat bed sewing machine & hammering and threads trimming.
Folding top edge of front part & Folding the top edge of back part keeping two sides raw edge
Attaching one edge of back zipper pocket lining on lower edge of zipper with folded top edge of back part by applying adhesive
Folding two sides of back top Patti & hammering
Attaching another edge of back zipper pocket lining on top edge of zipper with folded back top Patti by applying adhesive
Attaching EVA with two gusset & Folding top edge of two gusset & hammering
Stitching ring loop with square ring at marking position on gusset & threads trimming
Attaching both part of belt & hammering
Attaching rabose with bottom
Attaching two gusset with bottom by applying adhesive
Stitching front & back part with stitched gusset and bottom part & thread trimming
Stitching belt with gusset of bag & threads trimming
Attaching PVC on the attached foam of flap upper by applying adhesive
Attaching EVA sheet with two counter flap side strap
Attaching two counter flap side strap with counter flap by applying adhesive
Attaching EVA with counter flap bottom strap
Attaching counter flap bottom strap with counter flap by applying adhesive
Attaching flap upper & counter flap by applying adhesive
Fixing top part of magnet on the flap & Fixing bottom part of magnet on front part of bag
Preparation of Handy pocket
Folding four edges of zipper cut portion of back part inner lining and Attaching #3 no. nylon zipper with runner & puller at folded zipper portion of back part inner lining
Stitching inner zipper pocket lining with 3 No. nylon zipper & threads trimming
Stitching two inner gusset lining with front and back part inner lining & threads trimming
Edge of folded inner lining attached with the edge of bag body
Puller edge folding with glue
Puller setting with zipper runner by fitting o-ring of metal zipper
Cleaning and dressing
Inserting Bur code, Internet level, Price tag & safety label
Packing of Bag
0 200 400 600 800 1000 1200 1400 1600 1800 2000
RESULT OF THE PROJECT According to table-1
The existing production of the closing line-1 was 250 pieces Bag per day.Standard output of the line-1 (at 100% capacity) was 509 pieces per day.Total no of worker was 80.Work content (Minutes) per bag was 75.45So the efficiency of the existing line was 49.12%
According to table -2 & table -3
Standard output of the modified closing line -1 (at 100% capacity) could be 561Pieces Bag per day.Work content (Minutes) of proposed line is 68.37 minutes.So productivity increasing 10.21% by using same labour.Work content reduction is 7.08 minutes.
SUGGESTION AND RECOMMENDATION
1. Line layout should be balanced according to sequence of operation.
2. Show board may be made for every article to ensure correct specification
3. Less order may be avoided.4. Supervisor and worker need training.5. Attitude towards work should be positive.6. A preventive maintenance schedule should be strictly followed.7. Incentives may be introduced to skill enhancement.8. The sewing operator may be trained to keep hand away from balance wheel.9. Skilled operators must be appointed for critical operations.10. Line balancing and workers distribution may be done using standard times.11. A regular training program (Non-Technical and Technical) on transactional analysis,
Motivation, quality concept, productivity etc. could be organized.12. Workers should be encouraged to point out any inconstancies.13. Efficiency calculation should be done on monthly basis.14. Workers rating could be introduced according to the performance so that it acts as a
guide for improvement.15. The wage difference of machine operator and manual operator is very less; therefore
there is little motivation for skill enhancement. Wages difference should be more.16. After critical operation, there should be stage inspection.17. During production, rework may not be done which need to change thread.
THANKS TO ALL