CELLULAR LAYOUT

CASE STUDY
STYLE DESCRIPTION

BUYER NYGARD
SYLE 102
CLASSIFICATION TROUSER
OPERATION BULLETIN- CONVENTIONAL
IBG JORDAN
Operation Bulletin
Style #102 MACHINE REQUIREMENT WIP
Waiting Time
Total
Sl# Code Operation Machine SMV Target Manpower Kansai Single Needle Bartack 5T Overlock 3T Overlock Blind Hem WIP (NVA)
Output/Hr
1 M1 Pocket bag Overlock 5T O/L 0.95 63 2.5 3 158 0.38
2 M2 Pocket Attach SNLS 0.43 140 1.5 1 209 0.29 0.09
3 M3 Pocket Outline SNLS 0.26 231 1 1 231 0.26 0.03
4 M4 Pocket tacking SNLS 0.45 133 1.5 1 200 31 0.30
5 M5 Side Seam 5T O/L 0.84 71 2 2 143 57 0.42
6 M6 Inseam Attach 5T O/L 0.6 100 2 2 200 0.30 0.12
7 M7 Overlock backrise 5T O/L 0.33 182 1 1 182 18 0.33
8 M8 Mark Elastic Helper 0.18 333 1 333 0.18 0.15
9 M9 Attach Elastic 3T O/L 0.37 162 1 1 162 171 0.37
10 M10 Bottom Serge 3T O/L 0.26 231 1 1 231 0.26 0.11
11 M11 Blind Hem Blind Hem 0.28 214 1 1 214 16 0.28
12 M12 Press garment (seams) Press 0.33 182 1 182 32 0.33
13 M13 Label Attach SNLS 0.42 143 1 1 143 39 0.42
14 M14 Waist band tacking SNLS 0.18 333 1 1 333 0.18 0.24
15 M15 Elastic Smocking Kansai 0.57 105 1.5 2 158 175 0.38
16 M16 Bartack Front Bartack Mac 0.23 261 1 1 261 0.23 0.15
17 M17 Checking helper 0.3 200 1 200 61 0.30
Handling Time 1 67 200
TOTAL 7.87 22 2 5 1 8 2 1 541 0.89
100% 168
90% 151
85% 143
FLOOR AREA REQUIRED-CONVENTIONAL LINE

M1 M2 M3 M5 M6 M7 M9 M12 M13 M15 M16

2.64 meter
INPUT
Chec
M1 M1 M4 M5 M6 M8 M10 M11 M14 M15
king

13.75 meter

Length 13.75 m
Breadth 2.64 m
Area 36.3 m^2
OPERATION BULLETIN- LEAN LINE
IBG JORDAN
Operation Bulletin-CELLULAR LAYOUT
Style #102 MACHINE REQUIREMENT
Sl# Code Operation Machine SMV Target Manpower Kansai Single Needle Bartack 5T Overlock 3T Overlock Blind Hem
1 M1 Pocket bag Overlock 5T O/L
2 Pocket Attach SNLS
2.09 29 1 1 1
3 M2 Pocket Outline SNLS
4 Pocket tacking SNLS
5 Side Seam 5T O/L
6 M3 Inseam Attach 5T O/L 1.67 36 1 1
7 Overlock backrise 5T O/L
8 Mark Elastic Helper
9 Attach Elastic 3T O/L
M4
10 Bottom Serge 3T O/L 1.42 42 1 1 1
11 M5 Blind Hem Blind Hem
12 M6 Press garment (seams) Press
13 Label Attach SNLS
M7
14 Waist band tacking SNLS
15 M8 Elastic Smocking Kansai 1.59 38 1 1 1 1
16 M9 Bartack Front Bartack Mac
17 Placing back the Garment Helper
TOTAL 6.77 4 1 2 1 2 1 1
TARGET 100% 35
90% 32
85% 30
 CELLULAR LAYOUT
5TOL SNLS 5TOL 3TOL 3TOL 5TOL SNLS 5TOL

BHM
CELL 1 CELL 3

BTK KANSAI SNLS PRESS PRESS SNLS KANSAI BTK

BHM
CELL 4
CELL 2

BTK KANSAI SNLS PRESS PRESS SNLS KANSAI BTK

Length 9.11 m
Breadth 4.2 m
Area 38.262 m^2
COMPARISON
SL FACTORS CONVENTIONAL CELLULAR
1 Standard Minute Value 7.87 6.77
2 Manpower 22 20
3 Target per Hour 168 177
4 Floor Area (Sq.m) 36.3 47.82
5 Machine requirement 19 40
6 WIP 541 0
7 Waiting Time 0.89 0.67
8 Multi Skil Level Operator Not required Required
9 Changeover time 2days less than 1hrs