Productivity improvement through time study approach: A case study from an apparel manufacturing industry of Pakistan

Standard processing timings play an important role in efficient production management and are measured using work measurement techniques. Time study is a widely used work measurement technique in repetitive manufacturing processes. In present study, time study technique was used to enhance productivity of a garment production line in a work wear manufacturing factory. The factory consisted of 350 sewing machines and was producing work wears including trousers, vests, jackets and coveralls. Stop watch time study - analysis of existing set up - explored the existing time losses in production line caused by unevenness of work, excessive material transportation and higher work-in-process. Improvements were made through: (i) sequence of activities, (ii) tasks reassignment to the work stations and (iii) line balancing at predetermined cycle time. Hourly production charts were maintained at each work station to monitor outputs. The results of machine productivity were compared before and after employing changes. From results, 36% increase in average machine productivity was observed. Hence, it can be concluded that time study is an effective tool for increasing productivity in apparel manufacturing. The added advantages including optimization of material flow, balanced production line and reduced work in process were also achieved. The results of this study are useful for sewing factories making other woven, knitted and home textile products. In addition, football, shoe and gloves manufacturing industry may reef benefits from findings of this study.