# Introduction he polo shirt would be better named the tennis shirt, since it was first designed by Jean René Lactose, a world-class tennis player who was fondly called the alligator or crocodile because of his vicious playing tactics. Lactose, like many tennis players in the early 20th century, felt tennis garb was restrictive, as players had to wear long sleeved shirts and ties. In 1929, Lactose made the polo or tennis shirt out of pique cotton in a loose knit, with a button down collar that could be flipped up for extra sun protection, and thankfully no tie [1]. As dressing became less formal for men, the polo shirt migrated into popular culture as semi-casual wear. Ralph Lauren's brand Polo was helpful in setting the style of the polo firmly in place in the 1950s. These shirts have even become popular in school uniforms for private and often Catholic schools. While most private schools in the 1970s insisted on boys wearing the more standard non-knit cotton button down, now many simply require a polo shirt in the color the school wears. In the 1980s, Lactose brand polo shirts were for a time, a status symbol for both young men and women. manufacturers requires low inventory and quick response systems that turn out a wide variety of products to meet customers demand. It is especially in the apparel industry that managers are trying to develop their current systems or looking for new production techniques in order to keep pace with the rapid changes in the fashion industry. Therefore, to develop a new system, good observation is needed. However, to observe real manufacturing systems is very expensive and sometimes cumbersome [3]. In garment production, until garment components are gathered into a finished garment, they are assembled through a sub-assembly process. The production process includes a set of workstations, at each of which a specific task is carried out in a restricted sequence, with hundreds of employees and thousands of bundles of subassemblies producing different styles simultaneously [4]. The joining together of components, known as the sewing process which is the most labor intensive part of garment manufacturing, makes the structure complex as the some works has a priority before being assembled [5]. Furthermore, since sewing process is labor intensive; apart from material costs, the cost structure of the sewing process is also important. Therefore, this process is of critical importance and needs to be planned more carefully [6]. Assembling process flows from one station to another. In assembly line balancing, allocation of jobs to machines is based on the objective of minimizing the workflow among the operators, reducing the throughput time as well as the work in progress and thus increasing the productivity. Sharing a job of work between several people is called division of labor. Division of labor should be balanced equally by ensuring the time spent at each station approximately the same [7]. Since the late 1970s, the RMG industry started developing in Bangladesh primarily as an exportoriented industry and the domestic market for RMG has been increasing fast due to increase in personal disposable income and change in life style. # T The sector rapidly attained high importance in terms of employment, foreign exchange earnings and its contribution to GDP. Abstract-Though anybody could certainly get less expensive pools, wearing the Lactose with its tiny alligator insignia on the chest was considered highly fashionable. It was associated with the 1980s "Preppy" look [2] # G . e-mail: tanjimseu@yahoo.com The major importers are European Union, USA and Canada. Knit garments are exported to 148 countries and woven garments are exported to 132 countries [8]. The major buyers are Wal-Mart, target, Marks and Spencer, Tesco, Levi's, Zara, JC Penny, GAP, C &A, UNIQLO etc. It contributes more than 80% of total export earnings. Since buyer comes to this region for the lowest labor price ($0.11 per shirt for Bangladesh, $0.26 for India, $0.79 for Srilanka), the quality of the garments, efficiency and productivity of Bangladesh RMG sector remain ignored even in the tough competitive market. Factories in Srilanka operate at 80% -90% of efficiency, whereas in Bangladesh, according to some experts, productivity is between 35% and 55% of efficiency with very few exceptions. For the RMG sector in Bangladesh, productivity alone can make a difference between life and death [9]. II. # Objectives of the Study The main objective of the study is to determine the manpower and machine allocation for particular target. It is also designed to address the following issues: ? To determine line balancing ? To determine operational sequence of the manufacturing process of Polo-shirt ? To develop the target of the manufacturing process ? To increase the productivity of the company ? To make proper distribution of SMV ? To make better utilization of man, machine and materials III. # Methodology We have done this experiment in SM Knitwear Ltd. Bangladesh. We attempted this study for proper utilization of man and machine. We made a little bit change of existing line balancing and process layout for number of operations that was done by man power. In this experiment we used auto machines in some operations instead of man power and also find out the performed SMV after the modification of operations. A polo shirt, also known as a golf shirt and tennis shirt, is a form of shirt with a collar, a placket with typically two or three buttons, and an optional pocket. Polo shirts are usually made of knitted cloth (rather than woven cloth) usually piqué cotton or less commonly silk, merino wool, or synthetic fibers. A dress-length version of the shirt is called a polo dress. Earlier line was not balanced properly and nonvalue added helper was used. After study line has been balanced by time and capacity study according to target such as SMV for placket box 0.484, main label joint 0.396, side seam 0.77 and side slit tape attach 0.66. For which operation to achieve target need 1, 1, 2 and 2 operators consecutively but before balancing they used 2, 2, 3, 3 operators and also after over lock operation used helper. After study auto thread trimmer over lock machine has been set for those operations and two helpers have been reduced. Before study man power was 44 and after study man power is 38. Ultimately keeping the target same 6 persons have been saved. There are different kinds of polo shirt available in market and sewn in the ready-made garments manufacturing companies such as, polo shirt with single collar, polo shirt with double collar, polo shirt having rib cuff and without rib cuff, short sleeve and long sleeve polo shirt, polo shirt with slit band and without slit band, polo shirt with button and without button. Number of man power required to stitch a garments against a particular line target vary according to the type and style that is selected to stitch hence SMV of the polo shirt vary according to the style and number of operations carried out. And according to the style we can define as basic or critical. # Results And Discussion The estimated results have been presented in Table 1, 2, 3 and 4. From the Table 1 we have worked centering a basic polo shirt which contains the parts as front part, back part, placket, sleeve, collar and hem. Again from the Table 3 it is found that the number of single operations required to stitch the polo shirt is 32 (including operators and helpers) that was 34 before the study (Table 2). And required total number of man power is 44 (34 operators and 10 helpers) before study and 38 (30 operators and 8 helpers) after study. In the table 4, consider 110 % performance rating and 20% machine and personal allowances. Finally we have got the SMV 14.552 from the Table 4 for the above mentioned polo-shirt. V. # CONCLUSION This present study is based on an effective layout model of polo shirt where to use balancing process using short cut method. Here we have suggested following pitch diagram method to identify bottleneck operations and to solve the problem by 100 percent balancing. During the study we have seen thread trimming is being done manually using helper which is non value added unnecessary operation can be removed by setting auto trimmer along with machine or by using auto machine. The study shows that this balanced layout model has brought a better synchronization among man machine and materials increasing the efficiency and productivity. Traditionally operated garment industries are facing problems like unnecessary operations, wastage, rejection, poor line balancing etc. This problem can be eradicated by getting used with 5S method and making the working environment totally visualized [10]. Here to achieve better quality and cost effective production we can follow Standard Operation procedure (SOP) .When we will follow SOP we will be able to find unnecessary operations and due to follow standard procedure wastage and rejection will gradually come down at a tolerable level or zero. Thereafter in this way we can reach to our expected productivity and efficiency which is the main goal of our study. 1![Figure 1: Polo-shirt outline](image-2.png "Figure 1 :") ![Estimate assembles time of polo-shirt: Let, Performance rating = 110% Machine and personal allowances = 20% G e XV Issue II Version I](image-3.png "") 1Sl. No.Parts of a Polo-shirt01Collar02Placket03Front Part04Back Part05Sleeve06HemMaking process of Polo-shirtPlacket Rollingâ??"Placket Joinâ??"Nose Tuckâ??"Shoulder Joinâ??"Collar Joinâ??"Collar Pipingâ??"Upper Placket Top Stitchâ??"Lower Placket Top Stitchâ??"Back Neck Topâ??"Placket topâ??"Placket Boxâ??"Sleeve Cuff Joinâ??"Cuff Top Stitchâ??"Sleeve Joinâ??"Arm Hole Topâ??"Side Seam 2Year 201527XV Issue II Version I) VolumeJournal of Researches in Engineering ( GGlobal 3Sl. No.OperationsMachinesStitch typeMan powerHelperOperator1Placket position markHelper?12Placket fusingIron man?13Body scissoringHelper?14+Both placket joint on front partLS1N Lock Stitch25Placket nose tackLS1N Lock Stitch16Placket raw edge cutHelper?17Lower placket closeLS1N Lock Stitch18Upper placket closeLS1N Lock Stitch19Placket security tackLS1N Lock Stitch110Placket boxLS1N Lock Stitch111Body matchHelper?112Shoulder joint with pipingOLOver edge Stitch113Shoulder top stitchFLChain / Flat bed1Stitch14Collar markHelper?115Collar over lockOLOver edge Stitch116Collar jointOLOver edge Stitch217Neck pipingFLChain / Flat bed1Stitch18Neck top stitchLS1N Lock Stitch119Main label jointLS1N Lock Stitch120Sleeve match and shoulder pipingHelper?1cut21Sleeve jointOLOver edge Stitch222Bottom hemFLChain / Flat bed1Stitch23Care label jointLS1N Lock Stitch124Placket servicingOLOver edge Stitch125Side seamOLOver edge Stitch226Side slit tape measure and cutHelper?127Side slit tape attachLS1N Lock Stitch228Side slit tape top stitchLS1N Lock Stitch229Slit security tackLS1N Lock Stitch130Button attach and hole markHelper?131Button holeBH1N Lock Stitch132Button attachBS1N Lock Stitch1830Total man= 38 4Sl. No.OperationsAverage cycle time in secondPerformed SMV1Placket position mark170.3742Placket fusing180.3963Body scissoring150.334Both placket joint on front part430.9465 6Placket nose tack Placket raw edge cut21 21.330.462 0.469Year 20157 8Lower placket close Upper placket close19 190.418 0.418299 10 11 12 13 14 15Placket security tack Placket box Body match Shoulder joint with piping Collar mark Collar joint Shoulder top stitch18 22 15 20 20 18 36.660.396 0.484 0.33 0.44 0.396 0.806 0.44) Volume XV Issue II Version I16 17 18 19 20 21 22 23 24Collar over lock Neck piping Neck top stitch Main label joint Sleeve match and shoulder piping cut Sleeve joint Bottom hem Care label joint Placket servicing19 20 20 18 15 31 16 17 160.418 0.44 0.44 0.396 0.33 0.682 0.352 0.352 0.374Global Journal of Researches in Engineering ( G25Side seam350.7726Side slit tape measure and cut150.3327Side slit tape attach300.6628Side slit tape top stitch320.70429Slit security tack130.286© 20 15 Global Journals Inc. (US) © 20 15 Global Journals Inc. (US) ## Global Journals Inc. (US) Guidelines Handbook 2015 www.GlobalJournals.org * Principal, McKinsey's Frankfurt, Co-coordinator, McKinsey's Apparels, Apparel, Fashion & Luxury Practice AchimBerg 2011 88 * HEberle HHermeling MHornberger RKilgus DMenzer WRing Clothing Technology Berlin Beuth-Verlag GmbH 2004 59 * Apparel Manufacturing-Sewn Product Analysis REGlock GIKunz 1995 Prentice Hall 4 New Jersey * Introduction to Clothing Production Management AJChuter Blackwell Science 1988 * Introduction to Clothing Manufacturing GCooklin Blackwell Science 104 1991 * Materials Management In Clothing Production DJTyler 1991 BSP Professional Books Press 101 London * HEberle HHermeling MHornberger RKilgus DMenzer WRing Clothing Technology Berlin Beuth-Verlag GmbH 2004 68 * RRay Labor Management in Development Journal 2001. 2001 2 5 * AdnanMaroof Khan MdIslam Res. J. Management Sci 2 7 2013