Production Control Tools For Garment Industry

Prerequisite

Basic understanding of garment construction on how garments are sewn or assembled. Basic knowledge on different types of seams and stitches preferred. Students who do not have these prior knowledge may register with TaFtc to study “Basic Drafting and Sewing” and “Apparel Production”. Self study information on seams and stitches are also available in www.amefird.com

Course Description

This subject aims to improve the quality of sewing and increase production in any apparel manufacturing facility. The subject comprises of 5 modules; namely process analysis, operation analysis, time study, motion study and production design.

Process analysis - all the basic tools required for this course such as the basic flowchart symbols, naming of each sewing operation, using standard symbols and words to illustrate seams, stitches, machines and attachments will be taught.

Operation Analysis – this module covers Juki’s method of analyzing the operation rate and allowance rate in the factory by observation of workers working behavior. The operation rate and allowance rate is then used to compute the daily work flow.

Time Study – students will learn the skills on how to determine bottlenecks in the production line through time study.

Motion Study – this module covers the method of how to improve production using KAIZEN principles.

Production Design – this module covers the planning of a sewing production system, arranging people, machinery, equipment and materials in terms of space and time.

Who Should Attend

Line supervisors, factory/production managers, industrial engineering/work study team, quality assurance auditors, production planners.

Aims and Objectives

The aims of this subject are to:
     1.Equip the participants with the fundamental principles and tools in operation analysis, time and motion study and line balancing.
     2.To do a time and motion study in the factory.
     3.To be able to trouble shoot on existing production lines, identify problems and improve productivity.
    4.To design a efficient production layout.

Subject Content

Subject Topics

Sub Topics

Specific Learning Outcomes

Operational Analysis	Classification of workers behavior. Sample selection, observe, record and analysis to attain allowance rate/operation rate.	Understand factory conditions and workers behavior. Identify problems in factory. Calculate the allowance rate and operation rate.
Time Study	Measuring methods. Observation procedures. Determine operation checkpoint.	Identify cycle time for each process. To determine process time for each operation.
Motion Study	The Principles of KAIZEN. 4 principles of improvements. Systematic method of problem identification and definition. Motion economy.	Comprehend the principles of KAIZEN and the 4 principles of improvement. Identify wasted or inefficient motions. Comprehend motion economy to maximize efficiency of each motion.
Production Design	Production Format and System. Synchronization in the Division of Labor. Pitch time and productivity. Bottleneck and Organization Efficiency. Line Balancing.	Comprehend the various production formats and systems. Understand the necessity of synchronization in the division of labor. Distribute processes to operator using fundamental rules in synchronization and line balancing. Calculate pitch time, identify bottleneck, calculate organization efficiency.

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Course Code	:	PCTGI
Course Duration	:	24 Hours
Time	:	9.00 am – 6.00 pm
Course Fees	:	Actual Cost	SDF Grant	Amount to Pay
		S$550.00	S$48.00	S$502.00 (TaFf Members)
		S$600.00	S$48.00	S$552.00 (Non Members)