Why is it an Art..?
Because it needs special skill to combine number of operators for many different processes with various cycle times. The purpose is to get the smooth workflow, so there are several steps to be done:
- Identify the cycle time per each single process to produce a garment
- Determine number of operator(s) for all processes for a smooth workflow
- Assign the right operator(s) for each single process
Let’s do a simple calculation as per illustration below
If we look at the above then the number of operators should be:
We have identified the Cycle time on each process, and then do the proper Line Balancing, these mean nothing if we assign the wrong operators. Supervisors/line leaders will choose the operators based on their memory, so the potential bottleneck will always happen if we do not have the skill database of our operators.
Skill-Math will help us on this area, identifying skill of operators on each process, show availability on operators based on the needs at the sewing lines and at the same time monitor the skill trend for further improvement.
Less bottlenecks = Higher Productivity