An improved labour productivity improvement method as a continuous improvement tool for apparel manufacturing

Abstract

The purpose of this study is to introduce an Improved Method for Sri Lankan apparel industry as a continuous tool for improving the labour productivity through analyzing the activities and motions of sewing sections’ employees. The Improved method consists six steps: Identifying the work units, Motion Study, Activity Sampling, Data Analysis, Eliminating/ reducing unnecessary motions and activities, and Measure the labour efficiency. After measuring the labour efficiency, researcher comes back to the first step for further improvements as a continuous improvement tool. Data analysis and implementation of appropriate solutions are the critical part of this study. Percentage distribution of each activity of the job cycle can be analyzed well using the activity sampling technique. The results showed that talking privately, discussing work related things, idle siting, judgments, cutting excess threads are the critical Non-value added activities. Both Necessary Non-Value Added Activities and Non-Value Added Activities have to be eliminated from the process. Bottleneck of the motions can be identified through motion study. Activity Sampling Technique and Motions Study are the most significant steps of this study. Therefore, this is mainly primary data driven research. These techniques of analysis can be applied to other sectors of manufacturing regardless of nature of the product and working conditions.