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    Wip PDF

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    of 29

    WIP

    Work In Process
    By
    Ranjan Kumar Saha
    Associate Professor.
    NIFT-Mumbai
    What is WIP?
    • WIP is work in process.
    • The parts of the garment operation is not
    completely finished and is yet to complete
    , is considered to be WIP in the
    production line.
    • For e.g. a bundle of shirt that has every
    thing done but only ready collar need to
    be attached .
    Measurement of WIP
    • WIP can be measured in units of number or in
    units of time.
    • For e.g. if we know that an operation like
    attaching of collar takes 2 minutes/pc. And we
    have
    • 20 bundles in WIP and each bundle consisting of
    10 pcs. then the total WIP is
    no. of bundles X no. of pcs. in each bundle
    X work content /pc.
    • i.e. 20 x 10 x 2 = 400 minutes.
    Need of WIP

    • It is recommended that WIP should be


    there in progressive bundle system but
    that is up to a controlled limit , i.e. it can
    be from half hour to a maximum 2 hours.
    • In some factories it is seen the WIP is too
    high , you can find some operations that
    have days of inventory waiting to be
    processed. This is harmful for a factory
    Why the WIP should not be very
    high?
    • There is financially loss if the WIP is high , as it involves
    investment in raw materials .
    • The more WIP in line means more throughput time , and
    more the throughput time the more it effects on the
    cash flow of the factory.
    • The more WIP means , there is more chance of
    concealed problems in the bundles which are difficult to
    trace out.
    • The more WIP means large inventory and more difficult
    to control inventory and production.
    • Low through put time permits better co-ordination
    between buyer and manufacturer.
    How can we manage WIP?
    • WIP can be managed , If we can take
    following steps.

    1)Production planning:
    Production planning should be proper
    based on the production target , how
    many manpower and machine to be
    require.
    How can we manage WIP?
    2) Trims control:
    • What ever the trims require to manufacture the
    garment , should be kept ready in store before the cut
    bundle to be fed in the assembly line. An update
    inventory of the trims should be kept.

    • It is often seen that the cut bundles are fed in the line
    and a specific trim is not in the store.
    • For e.g. 5000 pcs. are cut and fed in the line but collar
    can not be attached as the labels are not received in
    the store yet.
    • This practice is not acceptable at all , as this could lead
    to other problems also .
    How can we manage WIP?
    3) Balancing:
    The production line to be properly balanced,
    in order to reduce the WIP.
    • If the line gets unbalance due to some
    reason , to regain balance in an
    unbalanced situation you can use utility
    operator, operator transfer or overtime.
    Effect of WIP on through put
    time:-
    • WIP & through put time.

    • The more WIP in production line mean


    more throughput time if throughput
    time increases in production line it can
    effect certain factors, like.
    Effect of WIP on through put
    time:-
    • The more the throughput time the more it effects on
    the cash flow of the factory.

    • There is financially loss if the through put time is


    high, as it involves investment in raw materials.

    • The more throughput time mean large inventory and


    more difficulty to control inventory & production.

    • Low through put time permits better co-ordination


    between buyer & manufacture.
    Clock Time:

    • It is defined as the total time available to


    an operator for doing work during the day.
    • It does not include the lunch time.

    • Clock time = on standard time + off


    standard time.
    Off standard time:

    • It is the time during which an operator is


    unable to do some work, due to factors
    which are beyond his control. I.e the time
    is spent in factory hours with out any
    productivity.
    • For. e.g. Power failure, machine
    breakdown or doing repairs for some
    other person
    On standard time:

    • It is the time made available to the


    operator for producing productivity work.
    • It can also be defined as the difference
    between clock time and off standard time.

    • On standard time = clock time - off


    standard time.
    SAM ( standard average
    minutes) :
    • It is defined as the time taken by a 100%
    normal operator to do a particular
    operation including the personal , fatigue
    and delay allowance.
    SAM produced:

    • It is defined as the standard minutes


    produced by an operator in a particular
    day . It is calculated as :

    • SAMs produced = number of pieces


    produced X standard minutes for
    that operation.
    Efficiency:

    • It is defined as the work done by an


    operator during the time available to him
    in a day .
    • It can be shown as ,

    • Efficiency = (SAM produced / Clock


    time ) X 100
    Performance :

    • It is a tool used to quantify the work


    content of an operator during the day.
    • It can be shown as,

    • Performance = (SAM produced on


    standard /On standard time ) X 100
    Utilization:

    • It is a tool used to determine the time


    percentage during which the operator
    worked in a day.
    • It can be shown as ,
    • Utilization = ( on standard time /
    clock time ) x 100 .
    What is production ?

    • Production is the process which convert


    materials (input ) into complete finished
    products (out put )
    • An apparel production system is an
    integration of materials handling,
    production processes, personnel, and
    equipment that directs work flow and
    generator finished products.
    Productivity:
    • Productivity is based on the relationship between inputs
    and outputs and is a measure of performance towards
    an established goal , i.e. the final expected out put or
    outcome.

    The concept of productivity is getting the maximum and


    valuable out put from ,
    • Each machine & method.
    • Each employee
    • Each shift/day/month/year
    • Each working space or working unit.
    • Each material given as input , and etc etc….
    Productivity:
    • Input:
    • Input may be one of the variables that go
    into the operation of a firm such as time,
    money , labour , materials, space and
    training.
    • Output:
    • Out put is final resultant product after the
    input.
    Partial productivity :-
    • Partial productivity in the ratio of output to one of
    input . for eg. Labour productivity (the ratio of
    output to labor input) is a partial measure.

    • Similarly , material productivity (the ratio of


    output to material input ) and machine
    productivity (the ratio of output to machine
    input) are example of partial productivity.

    • Operators productivity = 2000 pcs shirts / 100


    operators per shift = 20 shirts per shift.
    Total productivity :-

    • Total productivity is the ratio of total out


    put to the sum of all input factors thus a
    total productivity measures reflects the
    joint impact of all inputs in producing the
    output . it is a kind of a higher level of
    productivity assessment combining several
    or many partial productivity measures
    Advantage of partial
    productivity:-

    • Partial productivity measures are easy to


    understand and use. The data needed are
    both easy to obtain and easy to compute.

    • Partial productivity is also a good diagnostic


    tool for pinpointing improvement areas , so
    this can be used by the department or
    section in charge to evaluate its performance
    or to plan improvement.
    Disadvantage of partial
    productivity :-
    • If partial productivity is used alone , it
    can be misleading and may lead to
    mistakes .

    • Partial measures can not be used to


    explain overall cost increases
    Advantage of total
    productivity:
    • Total productivity measure consider all
    the quantifiable output and input
    factors, therefore it is a more accurate
    representation of the real economic
    picture of an enterprise.
    Disadvantage of total
    productivity
    • Total productivity measure does not tell
    the management of a firm which of its
    products or services is causing a
    decline or growth nor does it tell them
    which particular inputs – workers ,
    material capital energy or other
    expenses are being utilized inefficiently
    so that corrective action can be taken.
    Lead time :-

    • The amount of time between placing an


    order and merchandise delivery, we use
    to call lead time.
    Throughput time:-

    • the amount of time it taken for a style


    to go through the production process,
    starting form cutting to finishing we use
    to call throughput time.

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