Improving the Productivity in a Clothes Manufacturing Factory

Abstract

GM group includes two factories specialized in clothes manufacturing. The two factories are located in the first industrial zone of Obour City, Egypt. The first factory was established in 1980, specialized in the manufacturing of clothes for adults and named as GM home wear. In 2005, a new branch was established which specialized in the manufacturing of kid’s clothes, named GM kids. After investigating the production line in one of the clothes factories, it was observed that there are a lot of defective products which requires rework due to imbalance in production line and it accounts for 10 percent of the total daily production and the daily production rate ranges from 60 to 70 percent. The imbalance in production line resulted from the wrong distribution of worker’s efficiency and lack of complete knowledge of the state of the machine in the production line. In addition to the existence of a problem in the machine maintenance system. There is also a problem with the productivity measurement system. The project aims to improve the productivity by reducing defective products to 1 percent, improve the daily productivity to be at least 95 percent ,and balancing the production line using industrial engineering techniques such as work analysis, quality control and preventive maintenance. This reduction in defective products and the balance in production line between workers efficiencies and the state of machine will lead to improvement in productivity and quality level