that create or contribute to those effects (Hekmatpanah
2011). One of the underlying benefits of this method
is that it has nearly unlimited application in research,
manufacturing, marketing, office operations, and so
forth. One of its strongest assets is the participation and
contribution of everyone involved in the brainstorming
process (Hekmatpanah 2011). The ability of a causeand-effect diagram to clearly identify and categorize
factors that affect the performance of the system is one
of the major reasons for its adoption in this study.
2.3.4 Time study
The definition of time study was first coined in the
early 20th century in industrial engineering, referring to a quantitative data collection method where
an external observer captured detailed data on the
duration and movements required to accomplish a
specific task, coupled with an analysis focused on
improving efficiency (Lopetegui et al. 2014). The
time study basically involves timing and observing the
motion of the work associated with building the product. The collection processing times data are absolute
requirements for improving the assembly operations
in the facility (Ortiz 2006). The advantages of the
time study method over other work measurement techniques include (Babu 2012) (1) it helps in developing a
rational plan; (2) it helps in improving productivity; (3)
it helps in balancing assembly lines; (4) it provides the
time data for process design; and (5) it helps in determining operator skill levels. Nevertheless, conducting
a time study is time-consuming and very tiresome,
especially when the system has many elements to be
measured.
However, time study has been the most commonly
used as it determines accurate time standards, and
it is economical for repetitive type work. A vast
amount of research has been done using the time
study method. For instance, Senthilraja, Aravindan,
and Sathesh (2018) applied the time study technique
for improving the operators’ productivity in the rubber industry. While Khatun (2014) studied the effect
of the time and motion study on productivity in the
garment sector. The author postulated that the target
productivity can be achieved by time study. Time study
has fewer limitations than other work measurement
methods, including activity sampling, predetermined
time standards (PTS), and structured estimating (Babu
2012). The basic time study equipment consists of a
stop watch, study sheet, and time study board (Ortiz
2006). The steps for conducting a time study have been
reported in the literature (Babu 2012; Russell & Taylor
2011).
The number of timing cycles for specific activity
basically depends on the end use of the time study
data. For instance, if the time study data is to be used in
probability distribution analysis, then a greater number
of timing cycles or measurements give better results.
For each work element/task, the processing time can be
recorded 10 times (Kitaw, Matebu, &Tadesse 2010), or
15 times (Sudarshan & Rao 2014), 20 times (Kursun
& Kalaoglu 2009), or more; the higher the number
of measurements, the better the results. There are two
common methods of measuring time with a stopwatch:
fly back and continuous method (Puvanasvaran et al.
2013; Starovoytova 2017).
2.3.5 Brainstorming
Brainstorming or brainwriting is one of the most
common techniques used to generate ideas from an
individual or group of people. In most cases, it has been
applied in both educational, industrial, commercial,
and political fields (Al-khatib 2012). In the previous studies, brainstorming has been combined with
a fishbone diagram (cause-and-effect analysis tool)
for analyzing the current state of production systems.
For instance, Barton (2004) used brainstorming and
fishbone diagram to analyze and identify factors that
affect the throughput of the production process. Many
studies have shown the applicability of brainstorming
as problem-solving techniques. Al-khatib (2012) confirmed the effectiveness of using brainstorming as a
problem-solving tool.
2.3.6 Observation
Observation has been used for analyzing the current
state of the system amongst studies. However, it has
been used alongside interviews to capture more data on
the current state of the system (Gebrehiwet & Odhuno
2017). Observation is a very important tool when conducting process mapping and time study. For instance,
in garment assembly line, two major areas that were
observed on the sewing machines are machine working (positioning, sewing, and dispose) and machine
not working (waiting for repair, waiting for suppliers,
personal need for workers and idle) (Babu 2012). The
present study combined observation with process mapping for conceptual modeling of the garment assembly
line.
3 METHODOLOGY
3.1 Current state analysis
Southern Range Nyanza Limited (NYTIL) garment
manufacturing facility produces both knitwear and
woven-wear garment. However, other garment manufacturing facilities in Uganda and Kenya produce
either knitwear or woven-wear garment. The present
study was focused on the woven-wear garment production department because of its complexity. The
woven-wear garment manufacturing system consists
of nine production sections or stages as shown in Figure 1. The ABC classification method was employed
to prioritize the product style and the assembly line for
the study. In this case, a trouser assembly line was given
A- priority because of its complexity. Therefore, only
the trouser assembly line section for production of a
digital camouflage trouser model or style was selected
for this study.This was based on the fact that the trouser
assembly line entails a huge number of resources and
high uncertainty. Therefore, improving its efficiency
can lead to the overall improvement in productivity
78
2011). One of the underlying benefits of this method
is that it has nearly unlimited application in research,
manufacturing, marketing, office operations, and so
forth. One of its strongest assets is the participation and
contribution of everyone involved in the brainstorming
process (Hekmatpanah 2011). The ability of a causeand-effect diagram to clearly identify and categorize
factors that affect the performance of the system is one
of the major reasons for its adoption in this study.
2.3.4 Time study
The definition of time study was first coined in the
early 20th century in industrial engineering, referring to a quantitative data collection method where
an external observer captured detailed data on the
duration and movements required to accomplish a
specific task, coupled with an analysis focused on
improving efficiency (Lopetegui et al. 2014). The
time study basically involves timing and observing the
motion of the work associated with building the product. The collection processing times data are absolute
requirements for improving the assembly operations
in the facility (Ortiz 2006). The advantages of the
time study method over other work measurement techniques include (Babu 2012) (1) it helps in developing a
rational plan; (2) it helps in improving productivity; (3)
it helps in balancing assembly lines; (4) it provides the
time data for process design; and (5) it helps in determining operator skill levels. Nevertheless, conducting
a time study is time-consuming and very tiresome,
especially when the system has many elements to be
measured.
However, time study has been the most commonly
used as it determines accurate time standards, and
it is economical for repetitive type work. A vast
amount of research has been done using the time
study method. For instance, Senthilraja, Aravindan,
and Sathesh (2018) applied the time study technique
for improving the operators’ productivity in the rubber industry. While Khatun (2014) studied the effect
of the time and motion study on productivity in the
garment sector. The author postulated that the target
productivity can be achieved by time study. Time study
has fewer limitations than other work measurement
methods, including activity sampling, predetermined
time standards (PTS), and structured estimating (Babu
2012). The basic time study equipment consists of a
stop watch, study sheet, and time study board (Ortiz
2006). The steps for conducting a time study have been
reported in the literature (Babu 2012; Russell & Taylor
2011).
The number of timing cycles for specific activity
basically depends on the end use of the time study
data. For instance, if the time study data is to be used in
probability distribution analysis, then a greater number
of timing cycles or measurements give better results.
For each work element/task, the processing time can be
recorded 10 times (Kitaw, Matebu, &Tadesse 2010), or
15 times (Sudarshan & Rao 2014), 20 times (Kursun
& Kalaoglu 2009), or more; the higher the number
of measurements, the better the results. There are two
common methods of measuring time with a stopwatch:
fly back and continuous method (Puvanasvaran et al.
2013; Starovoytova 2017).
2.3.5 Brainstorming
Brainstorming or brainwriting is one of the most
common techniques used to generate ideas from an
individual or group of people. In most cases, it has been
applied in both educational, industrial, commercial,
and political fields (Al-khatib 2012). In the previous studies, brainstorming has been combined with
a fishbone diagram (cause-and-effect analysis tool)
for analyzing the current state of production systems.
For instance, Barton (2004) used brainstorming and
fishbone diagram to analyze and identify factors that
affect the throughput of the production process. Many
studies have shown the applicability of brainstorming
as problem-solving techniques. Al-khatib (2012) confirmed the effectiveness of using brainstorming as a
problem-solving tool.
2.3.6 Observation
Observation has been used for analyzing the current
state of the system amongst studies. However, it has
been used alongside interviews to capture more data on
the current state of the system (Gebrehiwet & Odhuno
2017). Observation is a very important tool when conducting process mapping and time study. For instance,
in garment assembly line, two major areas that were
observed on the sewing machines are machine working (positioning, sewing, and dispose) and machine
not working (waiting for repair, waiting for suppliers,
personal need for workers and idle) (Babu 2012). The
present study combined observation with process mapping for conceptual modeling of the garment assembly
line.
3 METHODOLOGY
3.1 Current state analysis
Southern Range Nyanza Limited (NYTIL) garment
manufacturing facility produces both knitwear and
woven-wear garment. However, other garment manufacturing facilities in Uganda and Kenya produce
either knitwear or woven-wear garment. The present
study was focused on the woven-wear garment production department because of its complexity. The
woven-wear garment manufacturing system consists
of nine production sections or stages as shown in Figure 1. The ABC classification method was employed
to prioritize the product style and the assembly line for
the study. In this case, a trouser assembly line was given
A- priority because of its complexity. Therefore, only
the trouser assembly line section for production of a
digital camouflage trouser model or style was selected
for this study.This was based on the fact that the trouser
assembly line entails a huge number of resources and
high uncertainty. Therefore, improving its efficiency
can lead to the overall improvement in productivity
78