GSD Manual For Students

© COPYRIGHT OF GENERAL SEWING DATA LIMITED C. 1996 Page 1
G EN E R A L S E W I N G D A T A
( G S D )
S T U D E N T M A NU A L
W A R N I N G
This manual is issued only to personnel attending an authorised
General Sewing Data course run by a qualified
and registered instructor.
The manual or any part thereof must not be reproduced without the
written permission of General Sewing Data Limited

NOTICE
• THIS MANUAL IS ISSUED ONLY TO PERSONNEL ATTENDING AN
AUTHORISED GENERAL SEWING DATA COURSE PRESIDED OVER BY
A QUALIFIED AND REGISTERED INSTRUCTOR. DO NOT ATTEMPT TO
USE THE DATA IN THIS MANUAL WITHOUT APPROPRIATE TRAINING.
• THE MANUAL OR ANY PART THEREOF MUST NOT BE REPRODUCED
WITHOUT THE WRITTEN PERMISSION OF GENERAL SEWING DATA
LIMITED.
• THE CONTENTS OF THIS MANUAL ARE SUBJECT TO CHANGE
WITHOUT NOTICE.
• THE ABOVE NOT WITHSTANDING, GENERAL SEWING DATA LIMITED
CAN ASSUME NO RESPONSIBILITY FOR ANY ERRORS IN THIS
MANUAL OR THEIR CONSEQUENCES.
• THIS MANUAL HAS BEEN ISSUED TO:
• MANUAL SERIAL NO: 010910015
• COMPANY NAME: Hasni Hosiery Mills (Pvt) Ltd
GENERAL SEWING DATA LIMITED
Suite 4 - 506 Green Place
Four Oaks Road
Walton Summit Centre
Bamber Bridge
PRESTON
PR5 8AY
Issue : 04 Document: GSD Student
Manual
Date : 01.07.01 Section : Notice
Auth : SJW/ME Page : 1 of 1

CONTENTS
SECTION DESCRIPTION PAGE
COVER FRONT COVER 1
NOTICE NOTICE 2
CONTENTS CONTENTS OF THE MANUAL 3
STRUCTURE GSD TRAINING COURSE STRUCTURE 4
1 INTRODUCTION 5
2 WHY MEASURE THE WORK THAT PEOPLE DO? 5
3 INTRODUCTION TO GENERAL SEWING DATA 6 - 7
4 METHODS TIME MEASUREMENT 8 - 13
5 THE DEVELOPMENT OF GENERAL SEWING DATA 14 - 15
6 GENERAL SEWING DATA (GSD) THE SYSTEM 16 - 17
7 HANDLING ELEMENTS 18 - 25
8 WORKING EXAMPLES - HANDLING ELEMENTS 26 - 27
9 GET & PUT ELEMENTS 28
10 WORKING EXAMPLE - GET & PUT ELEMENTS 29
11 DERIVATION OF SEWING CODES 30 - 31
12 THE CALCULATION OF SEWING TIMES 32 - 37
13 FIXED CYCLE MACHINES & PROCESS TIMES 38 - 40
14 MACRO’S 41
15 THE EFFECTS OF METHOD VARIATION 42
16 METHODS ANALYSIS & SMV CALCULATION EXERCISES 43 - 46
17 DISTANCE CLASSIFIED GSD CODES 47 - 48
18 ADDITIONAL MTM ELEMENTS 49 - 53
19 DECISION MODELS 54 - 62
20 INTERPRETATION OF CODES 63 - 64
21 GLOSSARY OF TERMS 65
22 TMU CONVERSION RATES & RELATIONSHIPS TO 66 - 67
CONVENTIONAL, PERFORMANCE RATING, SCALES.
DATABASE RELOCATION ADVICE SLIP 68

GSD PRACTITONER TRAINING COURSE OUTLINE
The following sub-sections are intended as a guide to aid the instructor and will be complimented and
amended according to the abilities of the candidates, at the discretion of the instructor.
Each session apart from tests and examinations will be interactive. The instructor will guide and
encourage the students as appropriate.
Day One
- Productivity and the Development of Work Study.
- Traditional Method Study and Work Measurement Weaknesses and Conflicts.
- Introduction to PMT Systems and MTM Core Data Principles.
- The Development of GSD, its Uses and Advantages.
- The General Handling Elements.
- The Get/Put Data.
- Exercises using GSD Handling Codes.
Day Two
- Theory Test (optional).
- Reinforcement Learning and Review of the General Handling Elements and Get/Put Data.
- The Derivation of Sewing Codes.
- The GSD Sewing Formula.
- Sewing Time Calculation
- Fixed Machine and Manual Codes.
- Exercises using GSD Handling and Sewing Codes plus MTM data.
Day Three
- Theory Test (optional).
- Reinforcement Learning and Review of Work to Date.
- Additional MTM Elements.
- Exercises using GSD Handling and Sewing Codes plus MTM data.
Day Four
- Reinforcement Learning.
- Distance Classification.
- Mock Examinations – Theory and Practice.
- Review of Mock Examinations
Day Five
- Theory & Practical Examinations.
REINFORCEMENT LEARNING AND REVISION GUIDE
It is intended that the reinforcement learning sessions within the course and the necessary extensive
revision outside the course time will be used to:
(1) Aid the instructor to assess the candidates ability to retain information and subsequently identify
topic areas in which the candidate is experiencing difficulty or is uncertain about their
understanding of the GSD system, and related topics.
(2) Indicate to the candidate the topic area in which they are to be assessed.

1. INTRODUCTION TO THE STUDENT MANUAL
The purpose of the manual is to guide the student through the various levels and applications of
the General Sewing Data system. It contains a detailed analysis of the system and practical
visualisation exercises which have been carefully structured to aid the student in the
interpretation of General Sewing Data. It also provides valuable supporting reference data for
use at any time, particularly in the students’ workplace.
2. WHY MEASURE THE WORK THAT PEOPLE DO?
In order to understand why such systems as General Sewing Data exist the student must
understand why we must measure work in the first place.
The purpose of measuring work is to determine the facts about how an individual operation or
group of operations are performed within the workplace.
This data provides management with key information that can be used to assess the
effectiveness of the people and machinery employed within the business.
This data then acts as a means for management to increase productivity through methods
improvement, skills training, performance boosting and problem elimination/reduction.
Traditionally Time Study has been utilised within the needle trades industries to establish time
standards for the processes involved when manufacturing products.
Time Study requires the practitioner to use of a watch, usually calibrated in 1/100 of a minute
and be competent at Rating Operator Performance. The latter requires that individual
practitioners fully understand the level of skill and speed necessary to complete the task at
predefined levels of output.
The weaknesses of this system are the accuracy of an individual’s Performance Rating and just
what is included in the Timed Work Cycle. These problems lead to inaccuracy and inconsistency
in applied standards, adversely affecting morale, output and quality standards.
The cost to individual businesses is extensive as many hours are spent in proving, or not
proving, time standards, as the case may be. Management’s credibility to determine achievable
targets etc. is questioned not only by the workers and their trade union representatives, but by
senior management as well. .
In summary Time Studied Standards lack integrity in many organisations.
Solutions to this problem were sought through the application of Predetermined Motion Time
Systems, and General Sewing Data (GSD) has become the market leader in the Sewn Products
Industry, and has replaced Time Study in many companies throughout the world.
In summary it can be said that:
NO MEASUREMENT = NO MANAGEMENT
INNACURATE MEASUREMENT = INEFFECTIVE MANAGEMENT
ACCURATE MEASUREMENT = EFFECTIVE MANAGEMENT

3. INTRODUCTION TO GENERAL SEWING DATA
3.1 OVERVIEW
General Sewing Data (GSD) was devised by Methods Workshop Limited, and published in
1978, and is subject to a continual development programme by General Sewing Data Limited,
using an MTM data base.
It is a Predetermined Motion Time System designed specifically for the sewn products
industries.
It is an easy to use and understand technique for Methods Analysis and the setting of Time
Standards for sewn product manufacture. It can be used to evaluate all operations, including
Cutting, Sewing, Pressing, Examination and Packing.
GSD recognises commonly occurring human motion sequences encountered in the sewn
products environment and describes the motion by means of codes. Each code has a definite
time value which takes account of the distances moved and the degree of difficulty of the
motions.
GSD consists of 25 codes at the First Level (General) which is supplemented by 11 codes at the
Second Level (Get & Put). Selected MTM codes are utilised to give complete coverage.
The system has been structured to enable the GSD practitioner to produce a logical, accurate
and consistent evaluation of method and, consequently, time. It is essential that the system is
applied correctly taking into consideration the Methods Study procedures set out below.
The use of GSD for determining best methods will facilitate the application of these procedures.
Time is expressed in Time Measurement Units (TMU’s) that can be easily converted to Basic
Minutes. (See Sections 4.4 & 4.5.)
It is recommended that the GSD practitioner adheres to the accepted Method Study Procedure
(ILO) but include training prior to the installation and maintenance processes.
Select
Record
Examine
Develop
Evaluate
Define
(TRAIN YOUR PEOPLE)
Install
Maintain
3.2 APPLYING ALLOWANCES WITHIN GSD ANALYSES
In order to compile a standard time from a GSD analysis it is necessary to apply allowances to
the Basic Minute Value (the Total TMU value in a GSD Analysis is converted to BM’s).
The application of allowances for Rest, (including relaxation and fatigue), and Contingencies is
the responsibility of each individual company and should be applied as per the policy guidelines.

3.3 RELAXATION ALLOWANCE ‘RA or PF’
An addition to the basic time intended to provide the worker with the opportunity to recover from
the physiological and psychological (fatigue) effects of carrying out specified work under
specified conditions and to allow attention to personal needs. The amount of the allowance will
depend on the nature of the job.
3.4 FATIGUE ALLOWANCE
A sub-division of the relaxation allowance intended to cater for the physiological and
psychological effects of carrying out specified work under specified conditions.
3.5 PERSONAL NEEDS ALLOWANCE
A sub-division of the relaxation allowance intended to cater for attention to personal needs.
SPECIMEN REST ALLOWANCE TABLES (POINTS) – BASED ON ILO WORK STUDY BOOK
ISBN No. 92 – 2 – 107108)
ALLOWANCE PHYSICAL STRAIN PTS
FORCE EXERTED Under 3Lbs 0
POSTURE Sitting Easily 0
VIBRATION Power Sewing Machine 2
SHORT CYCLE WORKING Cycles not repeated for long periods of time 0
RESTRICTIVE CLOTHING None Worn 0
ALLOWANCE MENTAL STRAIN PTS
CONCENTRATION / ANXIETY Guiding work by hand on Sewing Machine 10
MONOTONY Operative on repetitive work with
companionship
Competitive spirit & music
3
EYE STRAIN Normal factory work 0
NOISE Light assembly factory 0
ALLOWANCE PHYSICAL STRAIN PTS
TEMPERATURE / HUMIDITY Humidity < 75% , Temperature < 75 f 0
VENTILATION Reasonable ventilation but some draught 1
FUMES None 2
DUST No more than sawing wood 2
DIRT Less than a Dustman but more than an Office
worker
1
WET Normal factory operations 0
TOTAL 21
The above points total equates to approx. 12% on the ILO Chart and is inclusive of Tea Breaks
3.6 CONTINGENCY ALLOWANCE OR DELAY (CA or D)
A small allowance of time which may be included in a standard time to meet legitimate and
expected items of work or delays. Contingency Allowances usually vary from 2% to 5%, and
must be determined by individual companies, taking account of their individual circumstances.
Typical contingency allowances cover the normal occurrence of: Thread Breaks, Needle
Change, Thread Change, Spool/Looper Work, Technical Discussion. Other allowances may be
for setting up special work aids, attachments etc.

4. METHODS TIME MEASUREMENT (MTM)
4.1 PRE-DETERMINED MOTION TIME SYSTEMS
MTM is a generic term for a family of Pre-Determined Motion Time Systems (PMTS).
A PMTS is a methods analysis technique where time standards are produced as a by-product of
engineered or observed working methods. Basic human motions, singly or in groups, have been
isolated and a time standard for each motion determined by the nature of the motion and the
conditions under which it is made. The time values for all the manual motions are added
together resulting in a work analysis and time standard for any given manual operation.
4.2 MTM-1
As a result of work done at Westinghouse, H B Maynard, J L Schwab and J G Stegmerton, who
were the Methods Engineering Council, developed MTM and made it available to the world in
the 1948. There are 350 codes in MTM1.
At the time MTM was, quite correctly, hailed as a major step forward in the development of Work
Measurement and Methods Study techniques. Many people thought that the problems
associated with the existing techniques had been eliminated.
Unfortunately this was not the case, because using the system as a paper stopwatch soon ran
up against the problem of the time taken to generate accurate standards from the basic motion
level of MTM-1.
4.3 THE BASIC MOTIONS OF MTM-1
MOTION/ELEMENT CODE
PRINCIPAL MOTIONS
REACH R
GRASP G
RELEASE RL
MOVE M
POSITION P
DISENGAGE D
TURN T
APPLY PRESSURE AP
CRANK C
EYE ACTION ET & EF
BODY MOTIONS
FOOT MOTION FM
LEG MOTION LM
SIDE STEP SS
BEND , STOOP OR KNEEL ON ONE KNEE B, S MEK
ARISE FROM ONE KNEE AB, AS, AMEK
KNEEL ON FLOOR BOTH KNEES KBH
ARISE FROM FLOOR ON BOTH KNEES AKBK
SIT SIT
STAND STD
TURN BODY TB

4.4 THE BASIC MOTIONS OF MTM-1 CONT’D
The MTM-1 data card contains over 350 values, many of which are below 7 TMU’s. There are
almost 28 TMU’s in one second. This ensures that a considerable amount of time is spent by
the practitioner in generating an MTM1 motion pattern because of the high number of
decisions that have to be made, and the volume of writing involved. As a result MTM-1 was
not used as widely for the generation of time standards as it had been hoped by its originators.
There are two major variables associated with each principle motion, these being distance and
case. The data card consists of the 350 codes and their time values. These times are
expressed in Time Measurement Units. (TMU’s )
4.5 THE DERIVATION OF TMU VALUES
The original MTM1 study data was collected by the use of a camera. The speed of the camera
was 16 film frames per second.
The minimum unit of time used when developing the MTM 1 data was, therefore 1/16 second.
It was originally decided to work in decimal hours, 1/16 second = 0.00001735 decimal hours.
It became immediately apparent that this time was impractical to use so it was decided by the
designers that a new system of measuring time be developed.
The unit of measurement should equal 0.00001 hour. It was given the name, Time
Measurement Unit, which is readily abbreviated to TMU.
This time readily equates to TMU per second/ minute/ hour i.e.
1 Hour = 100,000 TMU’s
1 Minutes = 1667 TMU’s
1 Second = 27.8 TMU’s
The above times are considered to be applicable to Day Rate or non incentive working and
were described as MTM100 performance level or MTM Low Task.
When incentive working is introduced into the workplace a worker should produce more
TMU’s.
The higher performance level is described as MTM120 or High Task. This equates to:
1 Hour = 120,000 TMU’s
1 Minutes = 2000 TMU’s
1 Second = 33.36 TMU’s

4.6 COMPARISON OF PERFORMANCE RATING SCALES
There are a number of different Performance Rating Scales and the following chart shows the
relationship between the most common of these.
BEDAUX TAYLOR BSI & 75/100 MTM
Standard
80 –
67-
133 –
111-
100 -
83-
120 -
100
MTM High Task
MTM Low Task
Day Rate 60 -
0
100 -
0
75
0 0
It should be noted that “MTM” 120 High Task” corresponds with Standard Performance on all the other
scales, e.g.; Incentive rate of working by a skilled, well motivated worker e.g. 100% on the BSI and 75-
100 Scales.
Mathematically MTM 100 equates to 83% BSI and 75/100 scales, 111% on 100/133 scale, and 67%
on the 60/80 scale.
If minute values are to be expressed at Incentive Level then TMU values should be divided by 2000 to
convert them to Basic Minutes.
If they are to be expressed at MTM100 level then TMU values should be divided by 1667,
If they are to be expressed at any other performance levels, for example, 75 on the BSI and 75-100
Scales, they should be divided by 1500. The, none incentive, pace of working of a skilled operator is
expressed as a 75 performance.
Due to variations in incentive payment schemes within different companies or countries it may be
necessary to use different conversion factors.
It is possible to use conversation factors at any performance level to take account of any
circumstances, whether the level that any incentive payments commence or the targeted, none
incentive, level of performance.
However, the actual value of a TMU remains constant throughout the world.

4.7 MTM-2
The Development of MTM-2
“In 1965 the International MTM Directorate released a system known as MTM-2 which has been largely
based on work carried out by the Swedish MTM Association.
This system heralded a new era in data system design. For the first time a system was truly engineered
rather than derived empirically, as had tended to be the case with previous systems. What do we mean by
this?
MTM-1, the systems that went before it and most of the systems that succeeded it and grew out of it, were
based on analyses of work that had the objective of identifying the motions that were involved, classifying
them and looking for recurring combinations of those motions. The systems were built and if any attempt
was made to quantify them then specifications were written.
MTM-2, as stated before, was unique in that it was truly engineered. The specification for the system,
both in terms of speed of application and accuracy, was written first. Then the system was designed to
satisfy this specification”.
MTM-2 reduces the 350 MTM-1 codes to 39. The basic MTM-2 motions (important to the GSD analyst)
are set out, below, on the Decision Models and Table of Simultaneous Motions and the Basic MTM-2
Data Card:
D E C I S I O N M O D E L
GET DATA PUT DATA
No GA Yes
PA
Yes No
Yes GB No
PB
No Yes
GC PC
ARE ANY GRASPING
MOTIONS REQUIRED?
IS IT ENOUGH TO
CLOSE HAND OR
FINGERS IN ONE
MOTION
IS IT A
CONTINUOUSLY
SMOOTH MOTION?
ARE THERE OBVIOUS
CORRECTING
MOTIONS?

4.8 MTM CORE DATA
Researchers from the UK MTM Association and Methods Workshop (now General
Sewing Data Limited) developed a new PMTS called MTM Core Data.
4.8.1 DEFINITION
MTM Core Data is a Flexible, Multi Level, Predetermined Motion Time System that
can be entered at any level in order to achieve the level of accuracy required by
the user.
The principle on which Core Data was founded is that there exists one motion category,
XXX, with a known TMU value (12.9 TMU) and variances which can be applied simply
by counting up the number of movements. If the resultant accuracy is insufficient then
the motion categories, cases and/or distances are successively subdivided until a
satisfactory level of accuracy is achieved.
4.8.2 STRUCTURE
XXX
GXX PXX
GEX GDX PEX PDX
GAX GBX GCX PAX PBX PCX
The classifications form a pyramid. At the apex of the pyramid we have the Core Data,
XXX, i.e. any GET or PUT motion, of any case (difficulty), of any distance. Through
each of the levels of Core Data the complete data pyramid includes approximately 1440
values from a single value at the apex of the pyramid, down to around 700 at the base,
which roughly equates to MTM-1 level.
Therefore it will be seen that Core Data incorporates and integrates MTM-1 and MTM-2
plus any further possible vertical extensions (but not combinations) of MTM Data.
GET
REACH - GRASP - RELEASE
PUT
MOVE - LOCATE

5. THE DEVELOPMENT OF GENERAL SEWING DATA
5.1 DEFINITION
“GSD is a technique for Methods Analysis and the setting of Time Standards for the Sewn
Products Industries.
Reference - International Labour Office (Geneva) publication - Introduction to Work Study.
5.2 GENERAL SEWING DATA
GSD was developed using MTM Core Data, to provide a consistent, accurate and easy to
understand, easy to communicate methods analysis and time standards determination
technique. It was designed specifically for the Sewn Products Industries, and was researched
and developed within these industries.
GSD is transferable between locations and it recognises that variable work places, production
flow systems and batch sizes affect output.
The final system consists of 36 items of data in 7 categories with simple retrieval codes for ease
of application and understanding. Each item of data has a constant TMU value. There is also a
system of Sewing Code Derivation within the system and sewing formulae to facilitate the
calculation of machine time.
5.3 DATA DESIGN
Unlike previous systems, the specification for GSD was written prior to its design by recognising
the specific requirements of the Sewn Products Industries in terms of the speed of application,
and the accuracy and consistency of the results.
The system was then designed to satisfy the specification using MTM CORE DATA and modern
statistical theories. Each GSD code represents the frequencied, weighted average of the motions
contained in that motion sequence, taking account of the difficulty and distances moved in
carrying out those motions.
The objectives were to produce a simple, easy to understand system without sacrificing
accuracy, but at the same time balancing the administration requirements with the productivity
available from the system.
5.4 DATA SYSTEM CONCEPT
It was recognised in the sewn products industry that the work performed by a sewing machinist
could be generally categorised with the following sequence of events:-
1. Get part or parts and match.
2. Pre-form and/or put part(s) to machine foot.
3. Sew parts together with various re-alignments or addition of parts between sewing
bursts.
4. Trimming of threads or detaching work from the machine
5. Putting parts aside.
With the exception of various types of handling systems, e.g. progressive bundles, and machine
interference activities, these five elements of work invariably occur in sewing.

5.5 COMPARISON BETWEEN MTM2 AND MTM CORE DATA
For example, consider the variable workplace situation in the following elements of cutting
thread with a pair of scissors.
The MTM-2 analysis could be as follows:
LH RH
Holding Part GC30 Get Scissors
PC30 To Thread
R- Regrasp Scissors (Simultaneous motion)
PA5 Cut Thread
PA30 Aside Scissors
The skill of the system designer in compiling the codes would determine the final value of the
system.
The above analysis is in fact only one of 250 permissible MTM-2 analyses for these actions.
The scissors could be easy or difficult to grasp, positioning scissors to thread could be
accomplished with a PB or PC and scissors could be placed down anywhere.
With core data it is possible to write the average of the 250 available analyses, which would
be:-
LH RH
Holding Part GCX Get Scissors
PDX To Thread
R- Regrasp Scissors
PA5 Cut Thread
PAX Aside Scissors
The X representing a variable or unknown distance for which Core Data provides a value, the D
in PDX gives us a frequency average of PB or PC (VARIABLE CASE).
The Core Data gives us a total data system concept and from a one value system, or core XXX
(= 12.9 TMU), we can progress through the levels of data to the level where our ability to predict
accurately ceases within the circumstances of the industry being examined.

6. GENERAL SEWING DATA (GSD) THE SYSTEM
6.1 THE MAIN USES OF THE GSD SYSTEM
The system has been designed to aid the Industrial Engineer in the following:
• Costing Designs
• Line Balancing
• Investment Appraisal
• Pre-Production Planning
• Time Standards
• Operator Training
• Methods Rationalisation
6.2 THE ADVANTAGES OF THE GSD APPROACH TO METHOD & TIME STUDY
There are many advantages to be gained from the GSD approach and its design:
• Methods Sensitive
• Your Own Specifications
• Consistent
• Accurate
• Transferable between locations.
• Trace ability
• Predictive
• Easy to communicate
• Eliminates the need for Performance Rating.
• Easy to Understand.
• Designed specifically for the Sewn Products Industries.
GSD recognises:
• Quality and skill requirements.
• That varying batch sizes may have an effect on output.
• That varying production flow systems may have an effect on output.
• That variable work place layouts may have an effect on output.

IF YOU RELOCATE PLEASE SEND THIS ADVICE SLIP TO:
General Sewing Data Limited
Suite 4 - 506 Green Place
Four Oaks Road
Walton Summit Centre
Bamber Bridge
PRESTON
PR5 8AY
Tel: 01772 697730
Fax: 01772 697731
E-Mail: GSD@GSDHQ.com
SO THAT WE MAY UP-DATE OUR DATABASE (PLEASE USE BLOCK CAPITALS)
NAME : _________________________ LICENCE NO: __________________
COMPANY NAME : __________________________________________________________
COMPANY ADDRESS : __________________________________________________________
: __________________________________________________________
HOME ADDRESS : __________________________________________________________
: __________________________________________________________
CO. TELEPHONE NO : _________________ HOME TELEPHONE NO: _________________
===============================================================================
NAME : _________________________ LICENCE NO: __________________
COMPANY NAME : __________________________________________________________
COMPANY ADDRESS : __________________________________________________________
: __________________________________________________________
HOME ADDRESS : __________________________________________________________
: __________________________________________________________
CO. TELEPHONE NO : _________________ HOME TELEPHONE NO: _________________
E-MAIL ADDRESS : ___________________
===============================================================================

GSD Manual For Students

Recommended

Recommended

More Related Content

What's hot

What's hot (20)

Similar to GSD Manual For Students

Similar to GSD Manual For Students (20)

More from মোঃ ফুরকান উদ্দিন জুয়েল

More from মোঃ ফুরকান উদ্দিন জুয়েল (20)

Recently uploaded

Recently uploaded (20)

GSD Manual For Students