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undefined. VIETN AM N ATION AL UN IVERSITY – H O CH I MIN H CITY IN TERN ATION AL UN IVERSITY SCH OOL OF IN DUSTRIAL EN GIN EERIN G AN D MAN AGEMEN T Industrial Engineering in Merchandising Apparel Industry The study delves into the realm of industrial engineering within the apparel industry, emphasizing the pivotal role of ongoing productivity enhancement. Faced with the dual challenges of sustainability and profitability, the garment industry turns to time study as an instrumental tool for amplifying production rates and curtailing production time. By dissecting the manufacturing processes of T-shirts and Jeans, the study seeks to refine the efficiency of operators, machinery, pitch time, and individual capacities, while also addressing bottlenecks and process balancing to boost overall efficiency. The timely provision of pieces and order sheets emerges as a key factor in augmenting industry productivity. A Thesis presented by Nguyễn Phương Vân ID: IEIEIU19028 Advisor: Dr. DAO VU TRUONG SON Date: 04/03/2024.

[Audio] I introduced the topic of enhancing apparel industry productivity by dissecting manufacturing processes and addressing bottlenecks for my thesis. I explored existing research related to time study and industrial engineering then developed my methodology to identify the requirements for the proposed solution. The solution was developed based on my research and the results of my work were analyzed to draw conclusions..

[Audio] This thesis provides an in-depth look into the rapidly growing Vietnam garment industry. In 2023 the country's garment industry has seen strong development thanks to the signing of Free Trade Agreements such as the Vietnam-Japan Economic Partnership Agreement and the Comprehensive and Progressive Agreement for Trans-Pacific Partnership. Despite its significant contribution to the economy there are still challenges that need to be addressed. The focus of this study is the Hansoll Company with the goal of increasing its production efficiencies by applying Lean Six Sigma principles. By analyzing manufacturing processes and pinpointing bottlenecks this study aims to create recommendations to boost production and improve profit margins..

1.1 Background of the Study Industrial Engineering is crucial in the Garments Industry, optimizing production and ensuring quality. It integrates diverse sciences to boost efficiency and competitiveness in a market demanding variety and quality. 1 Interdisciplinary Approach Technical, Economic, Human, and Information Sciences converge in Industrial Engineering. 2 Market Adaptation Manufacturers adapt to consumer demands for diverse, quality products. 3 Productivity Enhancement Industrial Engineering techniques refine work methodologies to improve productivity..

1.2 Problem Statement Hansoll Company's sewing line department is grappling with high defect rates, as shown by Quality Control data. Standardizing products to minimize flaws is a critical goal. 1 Customer vs. Actual Demand Discrepancy between customer demand and actual production in 2023. 2 Quality Challenges Rising defect rates in sewing line operations. 3 Production Flow Refinement Focus on refining production flow to improve product performance. 99,214 98,957 98,485 96,803 99,388 98,479 97,817 99,143 90,000 91,000 92,000 93,000 94,000 95,000 96,000 97,000 98,000 99,000 100,000 JAN FEB MAR APR MAY JUN JUL AUG Customer demand & Actual demand in 2023 Customer Demand Actual demand % 13 % 14 % 15 15 % % 14 15 % 14 % 15 % % 12 12 % % 13 % 13 % 14 % 14 % 15 % 15 16 % JAN FEB MAR APR MAY JUN JUL AUG Defect Rate of Sewing Line from January to August 2023.

[Audio] Nguyễn Phương Vân is presenting a thesis for Vietnam National University – Ho Chi Minh City International University School of Industrial Engineering and Management which is a significant milestone in the apparel industry. The main goal of this study is to boost productivity and minimize costs through industrial engineering strategies. It seeks to review operations and carry out time and method studies for numerous garments. It also intends to design efficient layouts and balance lines as a means to increase productivity and reduce manufacturing costs. Ultimately the aim is to formulate a successful clothing manufacturing operation..

[Audio] The objective of this thesis is to investigate industrial engineering and time study in the apparel industry centered around the t-shirt and jeans production lines of Hansoll's Sewing department. Data will be gathered from Quality Control and Sewing departments over the course of several months in order to assess areas that need improvement that fit within the scope and limitation of the project. By examining and analyzing the manufacturing process and addressing existing bottlenecks it is expected that the results of the thesis will help to improve productivity..

[Audio] The apparel industry is a major contributor to the global economy and work-study is a vital component in attaining its success. Nguyễn Phương Vân's thesis examines the intricate pre-production and production processes involved in garment production in chapter two. It examines systematic development and refinement and the application of Six Sigma principles to enhance productivity eliminate bottlenecks and maximize the use of capacities. It also emphasizes the role of the industrial engineering department in conducting work-studies calculating standard minutes and promoting efficiency. Moreover it studies the historical context and effect of work-study in the textile and apparel sector..

[Audio] Nguyễn Phương Vân's thesis focuses on industrial engineering and time study in the apparel industry for improved productivity. Line balancing work-study calculating S-A-M and SMV D-M-A-I-C methodology and value stream mapping are discussed as the main facilitators of greater efficiency. Line balancing distributes the workload equitably within the production line making optimal use of workstations. Work-study is a method used to analyze activities to maximize resource use and set performance expectations. Standard Allowed Minutes and Standard Minute Value are two measurements of task time that evaluate process efficiency. The D-M-A-I-C methodology is a Six Sigma tool applied to weed out waste and optimize resource usage. Value stream mapping provides a pictorial representation of value-added and non-value-added flows identifying areas for improvement and aiding managers to set productivity and quality objectives..

[Audio] The methodology of shirt manufacturing is the focus of this chapter. To comprehend the process and challenges of meeting customer demand it is important to grasp the process flow chart for the sewing section. The chart subdivides the process into multiple steps each with its own difficulties. It begins with the cutting of fabric and culminates with quality control. Each step should have its bottlenecks identified and addressed to increase production efficiency and satisfy customer demand..

[Audio] In order to produce the garments there are two separate sewing lines which make components for shirts such as cuffs and sleeves and then the final garment is constructed by attaching those components. Our analysis showed that there is a deficit of 175 cuff pieces per shift which could heavily decrease the ability to meet customer demand. Examining and breaking down the manufacturing processes could help us reduce issues like this and ultimately increase productivity..

[Audio] Selecting the job or task for investigation is the first step of the work-study methodology. The second step involves collecting data through observation and recording. The third step is the critical analysis of the data to assess the purpose and sequence of each action. The fourth and final step is the development of the most efficient method to complete the job. Through implementing this methodology the productivity in the apparel industry can be enhanced as it allows us to break down the manufacturing process and identify possible bottlenecks..

Demand Satisfaction Analysis 90,000 91,000 92,000 93,000 94,000 95,000 96,000 97,000 98,000 99,000 100,000 JAN FEB MAR APR MAY JUN JUL AUG The Abilities To Meet Customer Demands Of Sewing Line Actual Demand Customer Demand.

[Audio] Nguyễn Phương Vân's study highlighted the significance of industrial engineering in the garment industry. Comparing processes application of time and method studies and productivity evaluation the research revealed numerous areas of inefficiency in the production of both The Birthday Dude t-shall and Denim 5 Pocket Long Pant. Subsequent actions such as worker substitution system enhancement and machine modernisation resulted in enhanced Standard Minute Values and effectiveness. This study demonstrates the potency of industrial engineering in increasing productivity in the apparel industry..

[Audio] Nguyen Phuong Van has proposed a system of tools for industrial engineering and time study in the apparel industry in her thesis. These tools consist of Slide Ruler Measurement Stopwatch Observation Pencil Eraser Item Tape Micrometer Sheet Time Study Forms Motion Picture Equipment and Time Reading Machines. These tools are intended to help enhance productivity by dissecting manufacturing processes and addressing any possible bottlenecks..

[Audio] For this slide I will be talking about Nguyễn Phương Vân's thesis focusing on industrial engineering and time study in the apparel industry to enhance productivity. This study broke down the manufacturing process into various operations and analyzed each one to address bottlenecks. Operation standard times basic times and standard times plus 15 percent were also investigated. Finally the study summarized all process S-M-V-s to find the overall S-M-V for the garment..

[Audio] This presentation focuses on the analysis of industrial engineering and time study in the apparel industry. We'll be looking at the equations of efficiency productivity and factory capacity to ultimately enhance productivity and address potential bottlenecks. The first factor to consider is productivity which is the output divided by the input multiplied by 100. This usually gives us a good starting point for measurement. Next we look at the line efficiency. This is the ratio of output to total manpower and working minutes times 100%. Lastly to calculate factory capacity we need to factor in machine count work hours and efficiency. In conclusion with these calculations we can more easily dissect manufacturing processes and ensure we meet our productivity goals..

[Audio] Improving productivity in the apparel industry requires attention to several key areas. Training employees so that they possess the needed knowledge and skill sets can help ensure efficient completion of tasks. Additionally ensuring the necessary materials are readily available in sufficient quantities can help to prevent idle worker time. Finally line management should be conducted efficiently to maximize productivity. Taking these measures into account can help to further increase productivity in the apparel industry..

[Audio] In Chapter 4's Solution Development phase various issues were identified in the production process of t-shirts. Through our thorough analysis of customer demands cycle time for each processing group and the current value stream mapping we have found an optimal solution to meet customer demands effectively and efficiently. We believe that this will help to enhance productivity in the apparel industry by dissecting manufacturing processes and addressing bottlenecks..

[Audio] My thesis examines industrial engineering and time study in the apparel industry in order to improve productivity. To achieve this I analyzed different manufacturing processes and identified the bottlenecks. During the define phase of the project I identified the problem and established specific goals. Through data collection I was able to create a graphical representation of the S-M-V before line 1. Additionally I balanced the T-shirt line with two goals in mind. The graphical diagram clearly demonstrated the average equal point production of some operations which are higher and lower than others. Finally I drew a conclusion that potential assembly defects may be caused by errors occurred during the marking cutting and sewing processes..

Measurement: Defects and Cycle Time Analysis 1 High Defect Rate Analyze the main causes of defects at each workstation to address the high defect rate and improve product quality. Months Quantities Defects Jan 33,029 4,177 Feb 33,560 4,693 Mar 33,716 5,058 Apr 33,573 4,904 May 33,484 4,634 Jun 33,823 4,990 Jul 33,008 4,548 Aug 32,956 4,794 Total 267,149 37,798 AVERAGE 33,394 4,725 Calculation of DPMO 1 Total Checked 33,394 2 No. of Defectives 4,725 3 % Defectives 14.15% 4 DPMO 141492.4837 5 Sigma 2.56 6 DPO 0.141 Group Jan Feb Mar Apr May Jun Jul Aug Avg.quan Pocket 1612 1632 1695 1639 1681 1696 1693 1654 1663 Front Body 1584 1616 1693 1623 1652 1654 1684 1674 1648 Back Body 1608 1625 1692 1633 1672 1685 1691 1710 1665 Sleeve 1564 1605 1690 1628 1642 1659 1680 1672 1643 Collar 1610 1621 1695 1613 1660 1676 1663 1698 1655 Assembly 1551 1595 1653 1598 1625 1610 1652 1662 1618 Finished 1604 1622 1689 1606 1654 1652 1661 1695 1648 Group Production Time Pocket 20.2 Front Body 21.7 Back Body 20.4 Sleeve 22.6 Collar 21.2 Assembly 24.6 Finished 21.2 0 5 10 15 20 25 30 1590 1600 1610 1620 1630 1640 1650 1660 1670 Pocket Front BodyBack Body Sleeve Collar Assemble Finished Production Time For 1 Detail Of Each Processing Group.

[Audio] A detailed analysis of the time it takes to manufacture apparel in the apparel industry has been presented in this slide. Operations are divided into 13 steps with the total lead time and inventory time between workstations studied for optimization and reduction of lead times. Additionally data is presented for each step including number of operations lead time cycle time and defects. This data can be used to locate bottlenecks in the manufacturing process and provide potential improvements in productivity..

[Audio] I explored how industrial engineering and time study can improve productivity within the apparel industry by performing a root cause analysis of production delays. This involved measuring the lead time cycle time takt time and idle time for each manufacturing step. High defect rate weak line balancing and lack of skilled workers were identified and analyzed as the major causes of production delays. My conclusions suggested that manufacturers can better identify and address any bottlenecks in the manufacturing process ultimately improving productivity..

[Audio] The figure shows that some workstations are dealing with a high load of tasks while others are not being used. Of the 49 workstations numbers 02 04 05 10 12 17 19 21 26 27 28 31 32 35 36 and 37 are having the heaviest workload. In particular workstation 12 has an especially heavy number of tasks which affects line balancing efficiency inventory amount and inventory time. It is important to analyze the issue in order to enhance productivity in the apparel industry by increasing cycle time takt time and the maximum cycle time..

[Audio] The improvement phase aims to enhance productivity in the apparel industry’s sewing department through the implementation of solutions such as the Lean Method standardized workload and quality control measures. Tasks such as pocket mouth fusing pocket mouth sewing pocket ironing front placket fusing front placket sewing and front placket ironing must be completed. A line balancing method including Lean Kanban systems and inventory time will be used to minimize redundancy and ensure the production of 25 products. Unskilled workers will have their cycle time Takt time and idle time reduced. The back yoke joint and the placket sleeve ironing and sewing will be carried out to complete the phase..

[Audio] Proposing to implement Lean Method and standardize workload for thread and fabric before operation to minimize redundancy productions and right-left hand for each processing group this Improvement Plan aims to ensure good thread and fabric quality as well as optimize the inventory of semi products. Agreeing on the type of thread beforehand is essential for achieving better results. It is expected that these measures will increase productivity in the apparel industry..

[Audio] This slide focuses on the root problems of productivity issues in the apparel industry to enhance productivity. We analyze the cause of productivity differences between processes to address the issue of workers caring more about producing more products rather than being aware of inventory problems. We must find a way to bridge the gap between worker engagement and inventory problems to enhance productivity in the apparel industry..

[Audio] The optimization of cycle times is an essential factor to consider when striving for efficiency in the apparel industry. In the sewing line there are multiple opportunities to reduce cycle times and increase productivity. By employing strategies such as providing working aids conducting comprehensive analysis of current operations and improving production layout we can make sure that the target takt time of 19 seconds is achieved or even exceeded. With these measures in place the apparel industry can enjoy higher efficiency and enhanced productivity..

[Audio] To reduce cycle time in the apparel industry work aids can be used to assist operators in handling parts during the sewing process. This will lead to increased efficiency and a decrease in cycle time. Additionally production process analysis can identify areas in need of optimization and utilizing techniques such as The Left – Right Hand Chart operation can help to further reduce cycle time and increase productivity..

[Audio] The production layout is a major determinant of efficiency in an apparel industry. To increase productivity it is necessary to analyze the current operations and arrange the layout of the workstations. By conducting a gathering of stations with spare time a reasonable dispension can be established to optimize processes and accommodate the new workstation numbers. With a close relationship in practice improved layout and production of the apparel industry can be achieved..

[Audio] Solution: To enhance productivity increasing the number of workers in the bottleneck operations should be considered. This can help reduce overall production time however it is important to weigh the cost benefit prior to implementation..

[Audio] Value Stream Mapping is a beneficial tool for industrial engineers to identify critical areas of non-efficiency within a manufacturing process. This thesis strives to create a Total Value-Added Time Control Plan to evaluate the long-term progress from Future Value Stream Mapping. Calculating total value-added time and non-value-added time allows us to evaluate the success of the plan in achieving lasting effectiveness. Our intention is to improve productivity in the apparel industry by analyzing manufacturing operations and tackling impediments..

[Audio] An analysis of the Standard Minutes Value (S-M-V--) within the apparel industry indicates that the implementation of lean principles and line balancing can reduce redundancy of production and optimize the inventory of workers and semi-products. Utilizing the right-left hand method for each processing group will increase efficiency and long-term productivity..

[Audio] The graph demonstrates that improved line balancing has resulted in a considerable diminution of Standard Minute Value or SMV. This cutback has fostered increased production capacity and enhanced product quality because of better resource arrangement and diminished waste. This has subsequently caused higher achievement rates and more fruitful production overall..

[Audio] This study determined that the application of additional operators to certain processes could reduce cycle time of production leading to higher productivity. The greatest impacts were seen in the placket sleeve ironing cuff sewing plus top stitch and hole stitch processes. Two operators were added to the placket sleeve ironing process decreasing cycle time from 27 seconds to 14 seconds. The cuff sewing plus top stitch process was reduced from 31 seconds to 16 seconds and the hole stitch process dropped from 30 seconds to 15 seconds with the same addition of two operators. These results are significant for the apparel manufacturing industry aiming to increase productivity and efficiency..

[Audio] Nguyễn Phương Vân's thesis presents an impressive achievement in industrial engineering and time study in the apparel industry. By thoroughly analyzing the manufacturing processes Vân pinpointed bottlenecks and deployed strategies to raise line balancing efficiency. Vân's efforts yielded a substantial enhancement with the line balancing ratio rising from 63.64% to 89.05% and the maximum cycle time dropping from 31 seconds to 19 seconds while the number of operators escalated from 51 to 57. This extraordinary progress is a significant contribution to the apparel industry reaffirming the importance of engineering in augmenting productivity..

Future Value Stream Mapping No Inventory Amount Inv.Time 1 Before WS 1 - - 2 Between WS 1 – 2 40 1000 3 Between WS 2 – 3 20 300 4 Between WS 3 – 7 20 400 5 Between WS 7 – 26 40 1000 6 Between WS 26 – 27 20 500 7 Between WS 27 – 28 40 920 8 Between WS 28 – 29 40 760 9 Between WS 29 – 30 40 800 10 Between WS 30 – 31 40 1200 11 Between WS 31 – 32 40 1000 12 Between WS 32 – 33 60 900 13 Between WS 33 – 34 20 320 14 Between WS 34 – 35 20 560 15 Between WS 35 – 36 40 1200 16 Between WS 36 – 37 40 840 17 Before WS 4 - - 18 Between WS 4 – 5 40 1120 19 Between WS 5 – 6 20 240 20 Between WS 6 – 7 - - 21 Before WS 8 - - 22 Between WS 8 – 9 40 680 23 Between WS 9 – 28 - - 24 Before WS 10 - - 25 Between WS 10 – 11 40 640 26 Between WS 11 – 15 20 340 27 Before WS 14 - - 28 Between WS 14 – 15 - - 29 Between WS 15 – 16 40 720 30 Between WS 16 – 17 40 880 31 Between WS 17 – 27 - - 32 Before WS 12 - - 33 Between WS 12 – 13 40 600 34 Between WS 13 – 15 - - 35 Before WS 18 - - 36 Between WS 18 – 19 60 1860 37 Between WS 19 – 20 40 400 38 Between WS 20 – 21 60 1680 39 Between WS 21 – 24 40 1440 40 Between WS 24 – 25 20 200 41 Between WS 25 – 29 - - 42 Before WS 22 - - 43 Between WS 22 – 23 20 400 44 Between WS 23 – 24 - - ➢ Calculate Current Value Stream Mapping In sewing line, some produce steps are parallel, so that the Processing Time is calculated by this ways: ❖ Total value-added time = CT01 + CT02 + CT03 + CT07 + CT26 + CT27 + CT28 + CT29 + CT30 + CT31 + CT32 + CT33 + CT34 + CT35 + CT36 + CT37 = 15s + 25s + 15s + 20s + 25s + 25s + 23s + 19s +20s + 30s + 25s +15s + 16s + 28s + 24 + 21s = 346 seconds. ❖ Total non-value-added time = each WS inventory time = 1,000s + 300s + 400s + 1,000s + 500s + 920s + 760s + 800s + 1,200s + 1,000s + 900s + 640s + 560s + 1200s + 840s = 11,700 seconds. ❖ Total Leadtime = TVAT + TNVAT = 346s + 11,700 s= 12,046 seconds = 3.35 hours. 68 0 38 0 36 0 76 0 38 0 68 0 76 0 72 0 60 0 76 0 90 0 32 0 28 0 60 0 56 0 76 0 34 0 68 0 64 0 34 0 72 0 76 0 40 0 108 0 76 0 114 0 72 0 28 0 32 0 0 20 0 40 0 60 0 80 0 100 0 120 0 INVENTORY TIME (s).

[Audio] To ensure the highest quality and productivity within the apparel industry two main processes must be carefully monitored and controlled defect rate control and lead time and cycle time control. A preliminary quality control system must be designed to ensure a consistent quality and performance. Furthermore a control process must be implemented to keep track of and maintain lead time and cycle time in the sewing line. With these control measures higher levels of efficiency can be achieved..

[Audio] As the apparel industry continues to evolve industrial engineering is playing a critical role in helping boost efficiency and productivity. The implementation of robotics in production the development of smart fabrics with embedded technologies and the integration of new technologies and processes into sustainable fabric production are all great examples of how modern innovative approaches are optimizing production. By efficiently and precisely dissecting the manufacturing process and addressing bottlenecks industrial engineering is now helping companies in the apparel industry stay ahead of the game and bring products to market faster and better than ever before..

[Audio] The slide of this Industrial Engineering research project focuses on its experimental design. To ensure its validity and reliability various experiments will be conducted to evaluate and measure the results. These experiments include capacity study time study operation breakdown actual layout line balancing and bottleneck analysis. The purpose of these experiments is to improve industrial engineering in the apparel industry and enhance productivity..

[Audio] I applied Lean Six Sigma techniques to the garment industry in my thesis to increase productivity. The outcomes were very positive with Total Lead Time reduced by 25.22% and Max. Cycle time decreased by 38.71%. Additionally P-C-E ratio WIP Time and Defect percentage also improved significantly..

[Audio] Nguyen Phuong Van's thesis addressed key corporate issues using tools such as work design line balancing and Kanban pull system design. These tools gave a variety of benefits offering insights on how to increase productivity within the apparel industry. Nevertheless the study was limited to two main products and not all sewing line issues were addressed. Furthermore the data collected was not exhaustive with practical recommendations yet to be implemented in order to measure their effectiveness..

[Audio] I explore the idea of improving productivity in the apparel industry by dissecting manufacturing processes and addressing bottlenecks. Additionally factor levels at the company need to be conducted improvement tools should be implemented throughout the company and changeover time and redesign should be researched and developed to eliminate waste. Actual data should be collected after the improvement process and control charts should be used to evaluate the results..

[Audio] My research in industrial engineering and time study in the apparel industry has a focus on improving productivity. I have studied the theoretical aspects and practical applications of a variety of processes production planning and machinery as a way to analyze and address bottlenecks. As part of this I've examined the necessity to be adaptive to the changing demands of industrial environments..

[Audio] To enhance productivity in the apparel industry understanding the manufacturing processes and identifying bottlenecks is key. To utilize productive time and resources efficiently two approaches are necessary. Conducting time studies to understand how much time is needed to complete each process and where time expenditure can be reduced through expert training is one approach. The other involves ensuring material availability for optimal production flow. Additionally a tailored line balancing technique should be used on the sewing line to ensure all resources are used efficiently..

[Audio] Concepts of line balancing are crucial for improving productivity in the garment industry. Nguyen Phuong Van has highlighted how optimization of the sewing line can cause substantial improvements in production. Line balancing methods are indispensable in improving industrial engineering and time study in apparel production. Deconstructing manufacturing processes and tackling blockages can reveal the highest level of efficacy. This study is highly relevant for rising productivity in the garment sector..

[Audio] A discussion of assembly line balancing techniques is presented here focusing on three specific approaches: genetic algorithm balancing largest candidate rule algorithm balancing and heuristic line balancing technique. Genetic algorithm balancing involves arranging a production line so that each task is evenly distributed. The largest candidate rule algorithm balancing is an effective way of utilizing labor in the garment industry. Heuristic line balancing techniques enable the simulation and design of a clothing assembly line for optimum productivity. All the techniques present are beneficial in managing a production line and increasing productivity..

[Audio] Industrial engineering principles such as time study and line balancing are effective in optimizing manufacturing efficiency. It is essential to constantly monitor the production line in order to secure lasting improvements and successful operations..

[Audio] Acknowledging the sources of information used for Nguyen Phuong Van's thesis the authors listed here have helped to identify assembly line balancing techniques in the clothing industry in order to enhance productivity. These sources include Eryuruk S.H Chen J C Chen C C Lin Y J Lin C J and Chen T Y as well as Klaoglu F and Baskak M Appreciation goes out to them for their contributions to Nguyen Phuong Van's thesis. Thanks for your attention..