Abstract:

Purpose- For the garment industry proper utilization of machines & manpower is very important to make a profitable business in this competitive global market. The man-machine ratio (MMR) gives an indication to the management about the indirect cost of the factory. Higher MMR can be a cause of low profit margins. However, there was not any standard MMR for the factory. It depends upon various factors like product type, machine type, production system, etc. Eliminating the waste from the process can help to reduce the manpower. However optimum use of the manpower can lead to optimum MMR.

Methodology- A kid's wear manufacturer’s data is considered for this project. Understanding the department involved in that factory. How each department contributes to the factory MMR. Understand the product portfolio & take three main products that consume 80% of the total production time that the factory has. Eliminate some waste from the process & implement new processes. Analysis & comparison before the new process & after the new process data.

Findings- In a few operations, it has been found that the garments have been overly processed & that doesn’t create any value addition. Removing that waste will give a better MMR score for the factory. In this project, 38 manpower are reduced from the current process by reducing one of the Muda (over-processing). By this study, it has been found that MMR is optimized from 2.10 to 1.99. This helps the factory become more cost-effective by reducing the cost of 60 lakh per annum.

Keywords- Man-machine ratio, Garment industry, Kid wear, Profitability, Kaizen.

Cite:
Sourav Ghosh, "OPTIMIZING THE MAN-MACHINE RATIO TO MAKE THE FACTORY MORE COST-EFFECTIVE", IARJSET International Advanced Research Journal in Science, Engineering and Technology, vol. 11, no. 1, 2024, Crossref https://doi.org/10.17148/IARJSET.2024.11116.

| DOI: 10.17148/IARJSET.2024.11116