Application of Industrial Engineering (IE) Techniques in Garment Industry - Textile Learner

7/29/2016
ApplicationofIndustrialEngineering(IE)TechniquesinGarmentIndustryTextileLearner
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ApplicationofIndustrialEngineering(IE)Techniques
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IndustrialEngineering:
The garment manufacturing industry faces many global challenges due to various factors
including competition, increased production costs, less productivity/efficiency and labor
attribution. So, there is a need to focus and concentrate on identifying the real issues, taking
corrective actions suited to the specific industrial centre of the unit, empowering the technical
and managerial staff by enhancing their knowledge and ability, analysing orders efficiently and
decidingwhetheractionsareviableforthecompany.
http://textilelearner.blogspot.in/2013/03/applicationofindustrialengineering.html
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Theworldeconomyhaschangedinsignificantwaysduringthepastseveraldecades,especially
in the areas of international trade and industrial organization. Two of the most important new
features of the contemporary economy are the globalization of production and trade. Therefore
todays technological systems are characterized by orientation to productivity this can be
achieved through the apparel engineering. This paper introduces the various concepts and
methods that have been used in Industrial Engineering as a part of Apparel Engineering in
Garment industries. Generally, Industrial Engineering is defined an approach applied to all
factors, including human factor involved in the production & distribution of production and
services.
NowwecandefineIndustrialEngineering(IE)as,
Industrial engineering is concerned with the design, improvement and installation of integrated
system of man, machine and equipment drawing upon specialized knowledge and skill in the
technical, economics and human sciences, either with the principles or methods of engineering
analysisanddesigntospecify,predictandevaluatetheresultstobeobtainedfromsuchsystem.
NatureoftheWorkinIE:
Industrial engineers determine the most effective ways for an organization to use the basic
factorsofproductionpeople,machines,materials,information,andenergytomakeorprocess
aproductorproduceaservice.Theyarethebridgebetweenmanagementgoalsandoperational
performance. They are more concerned with increasing productivity through the management of
people,methodsofbusinessorganization,andtechnologythanareengineersinotherspecialties,
whogenerallyworkmorewithproductsorprocesses.
Tosolveorganizational,production,andrelatedproblemsmostefficiently,industrialengineers
1.Studytheproductanditsrequirements
2.Usemathematicalmethodstomeetproductrequirements
3.Designmanufacturingandinformationsystems
4.Developmanagementcontrolsystemsforfinancialplanningandcostanalysis
5.Design production planning and control systems to coordinate activities and control
productquality
6.Designorimprovesystemsforthephysicaldistributionofgoodsandservices
7.Determine which plant location has the best combination of raw materials availability,
transportation,andcosts
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8.Developwageandsalaryadministrationsystemsandjobevaluationprograms
ResponsibilitiesofIE:
Though the time study and motion study are the most common function of Industrial engineer,
thesomeotherresponsibilitiesare
POPULARPOSTS
1.Planninglayouts
2.MonitoringProductionflowsystem
TypesofBra|DifferentTypesof
Bra/BrassiereforWomen
3.Deicidethemachinesandattachmentsforallstyle
4.Paysystem
PartsofaSewingMachineandTheir
Functions|DifferentPartsofHand
OperatedSewingMachine
5.Monitoringandimprovetheoperatorperformance
6.Operatortraining
7.Productioncontrolsystem
8.Qualitycontrol
9.Others
TextileCalculation|DifferentFormula
ofTextileCalculation
ProcessFlowChartofGarments
Manufacturing|Sequenceof
GarmentsProductionProcess
TextileManufacturingProcess|
ProcessFlowChartofTextile
Therearesomebasicterms,whichareimportanttoknowbeforelearningIE.Ashortdescription Manufacturing
BasicsTechniquesofIndustrialEngineering:
ofthesetermsarehighlightedbelow:
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CapacityStudy:
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achieving the performance measured by the study. The major Need for capacity study is to set
TextileDyeingMachine
Itisexactlythemeasureoftheoperatorsameascapability.Itmeanstheoperatoriscapableof
Quotas,tomotivateoperator,andtomeasuretheproductionssectioncapacity.Bymeasuringthe
individualoperatorcapacities,supervisorcandeterminetheoverallcapacityoftheirsection.Itis
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simplythesomeofindividualcapacity.
TextileBlog
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Procedure:
1.Useofstopwatch
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2.Measurethetimestudy
3.Averagethetimecycle
Thisaveragecycletimemeasurestheoperatorabilitytodotheparticularjob.Itsthemeasureof
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the skill of particular operator. Because the Industrial Engineers want to measure the skills and
abilityoftheoperatorintheiraveragecycletime.
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artificials...
BenefitsofCapacityStudy:
TextileManufacturing
Process
Textilemanufacturingisa
complexprocess.Itstarts
fromfiber...
ApplicationofDyes
Therearedifferenttypes
ofdyesfordyeingtextile
goods.Thesedyes...
ColorFastnessTests
Colorfastnessmeans
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1.Checktargets
2.Motivateoperators
3.Measuresectionproductioncapability
MethodStudy:
Methodstudyisthesystematicrecordingandcriticalexaminationofexistingandproposedways
of doing work, as a means of developing and applying easier and more effective methods and
reducingcosts.
Theprocedureswhichneedtodofollowwhiledoingmethodstudyaregivenasfollows.Thereare
sevenstepstobefollowedbyindustrialengineerstodomethodstudytheyare,
Undergarmentsor
Underwear
Itisveryimportantwear
becauseofitsfunctional
andappearancebeauty...
TextileCalculation
Calculatethelengthofa
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weight2.083lb...
ArticlesonIndustrial
Engineering(IE)
16articlesonIndustrial
Engineering.......
1.Selecttheworktobestudied
2.Definetheobjective
3.Recordtherelevantinformationanddata
4.Examineinformationanddata
5.Developtheimprovedmethod
6.Installimprovedmethod
7.Maintaintheimprovedmethod
8.Workmeasurement
TimeStudy:
Workmeasurementiscarriedoutbytimestudy.Timestudyisaworkmeasurementtechniquefor
recording the times and rates of working for elements of a specified job carried out under
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specifiedconditionsandforanalyzingthedatasoastoobtainthetimenecessaryforcarryingout
thejobatalevelofperformance.TheconceptofRatingisfundamentaloftimestudy.Ratingis
the process used by industrial engineer to compare the actual performance of the operator with
operator mental concept of normal performance. The rating is the numerical values used to
denote the ratio of working. In order to rate the operator ether must be a defined level of
performance to compare with, an average level. For this the industrial engineers apply the
conceptofaStandardoperator.Astandardoperatorisafullytrainedandmotivatedtoperforma
definedtaskandis,bydefinitionaverageintermsofhis/herworkplace.
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Thestepstodothetimestudyisasfollows,
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1.Observethejobandanalysetodeterminetheelement
2.Rateeachelementtocomparewiththeacceptedstandard
3.Usethestopwatchtotimeeachelement
4.Averagetheselectedelementtimes
5.Multiplyaverageelementtimebyrating
6.Addthebasictimeforalltheelement
7.Addallowances
Heretheelementsarethesmallcomponentsintowhichanoperationisdividedforstudypurpose.
They are selected for the convenience of the observation, measurement and analysis. These
elementsshouldbeclearandfullydescribableduringthedatapresentationandanalysisthat.
OperatorPerformance:
Basicallytheoperatorperformancecanbemonitoredwiththehelpofthreeefficiencyfactors.
1.Singlecycleefficiency
2.Onstandardefficiency
3.Globalefficiency
Singlecycleefficiency=[Targetsinglecycletimeinminutes(SC@100%)]/[Averageobserved
singlecycletimeinminutes(SCaverage)]
Hereweareconsideringthecycletimeonly.
Onstandard efficiency = [Operator production SAM per piece for the operation] / [Working
timeinminutesOffstandardtimeinminutes]
Heretheunproductivetimeisnotconsidered.
OffstandardTime:
Thetimespentbyanoperatorathisworkunderaconditionthatisnotconsideredasproductive.
Typesofoffstandard
1.Machinebreakdown(m/cfailure,threadcuts,needlebreakage,etc.)
2.Waitingtime(NoWIP,Waitingforthebundle)
3.Qualityproblems
4.Nofeeding
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5.Unfamiliarjob(Workingotherthanherregularoperation)
6.Training
Global efficiency = [Operator production SAM per piece for the operation] / [Working time in
minutes]
Here,thetotalworkingtimeisconsidered(evenunproductivetimeisalsoconsidered).
Followups:
This requires that someone checks on and stays with something until desired results are
achieved.Anyprojectbeingimplementedsuccessfullymayfailifthefollowupisnotconsistent.
Herewearegoingtoconcentrateonoperatorperformancefollowup.
BenefitsofOperatorFollowups:
1.Improveperformance(motivate)
2.Provejobquotas
3.Spottroubles
Typesoffollowups
1.Bundlebybundlefollowup
2.Bundlediagnosis
BundlebyBundleFollowup:
This followup is done when the operators onstandard efficiency is much less than his single
cycleefficiencyinthatoperation.
Single cycle (SC) efficiency is arrived considering the cycle time taken by the operator to
complete each piece. Whereas the onstandard efficiency is arrived considering the pieces
producedduringtheproductivetimespentinthatoperationforadefiniteperiodofworkingtime.
So, if the onstandard efficiency is much less than her single cycle efficiency, it means the
operator is unable to maintain the pace in all the pieces when she is working for a long time.
Duringthiscondition,thebundlebybundlefollowupwillhelpinfinding/solvingtheproblemsthat
occurbetweeneachbundle.
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BundleDiagnosis:
Thisisdonewhentheoperatorssinglecycleefficiencyoftheoperationisless.
ProcessofBundleDiagnosis:
1.Todoabundlediagnosis,astopwatchandtheformatisrequired.
2.Writedownthedescriptivedatarequired(IE,operator,operation,instructor,etc.).
3.DeterminetheSAMsforthenumberofunitsinthebundle.
4.Measurethetimeforeachactivityoftheoperatorandwriteitintheappropriatecategoryin
theformat.
5.After finishing the bundle, calculate the bundle efficiency, the single cycle efficiency and
compareagainsttheSAMs.
KeyPointsforBundleDiagnosis:
1.Donotinterfereintheoperatorswork
2.Bealertandpreventanyinterruptions
3.Writedowneverything
4.Analyzetheinformationandobtainyourconclusions
Itisequallyimportantthattheconclusionsobtainedturnintospecificactionsthatcanbetakento
improvetheoperatorsperformance.Performbundlediagnosisandgiveyourcommentsclearly.
WorkinProcess(WIP):
Thesemifinishedorfinishedgoodswhichtransportedfromoneworkstationtonextworkstation
arecalledworkinprogress.
1.WIPismadeupofallgarmentsandtheirpartsthatarenotcompletelyfinished.
2.Itcanbemeasuredinunits(pieces)ortime(minutes).
Forexampleifanoperatoratakes0.8minuteperpiecetostitchandifshehas3bundlesof10
pieceseachtobeprocessed,thentheWIPinthatworkstationis30piecesor24minutes.
NeedtoControlWIP:
TwomajorcostareascanbereducedifWIPiscontrolled.
1. Investment in inventory Inventory is the money invested in raw materials. If the inventory is
notmovedthroughtheplantquicklythenitaffectscashflowdirectly.
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2.Abilitytoreducetheproductioncycle
Byhavinglowinventorybetweenoperations,garmentsusuallyhavelesswaitingtimeand
go through the production cycle in less time. Large inventory levels between the
operations keep the goods waiting longer to be processed. This increases the overall
throughputtime.
Lowthroughputtimepermitsbettercoordinationbetweensalesandproduction.
Lowcycletimesgivemanufacturerstheabilitytohandlemultiplestyles.
Clients/buyers are looking for the factories that can meet production schedules, that can
handle multiple styles, and that can handle low inventories which will reduce their
investment.
ThefactoriesthatworkwithlowWIPonlywillbeabletosustaininthepresentmarket.
HowtoManageWIP?
TheWIPcanbemanagedbyfollowingtheactivitiesgivenbelowstrictly.
1.Productionplanning
Thisrequiresplanningfrommarketingandsalestodeterminethetype,periodandquantity
ofproductstobeproducedinthefactory.
Efficientpreproductionteam(sampling,R&Dandmerchandising)shouldplayakeyrolein
orderselectionandpreparatoryactivitiesbeforestartingthestyle.
2.Trimscontrol
Trimsarebuttons,zippers,labels,thread,elastics,andsoon.
Allthetrimsshouldbeinhousebeforecommencingthebulkproduction.
Anupdatedtrimsinventoryreportshouldbekept.Theunavailabilityofevenasmalllabel
couldstoptheproduction.
3.Productionbuildup
Loading should be done based on the datewise production build up plan, prepared by
consideringthecapacityofthesewingline.Iftheloadinggreatlyexceedsthequantitythat
thelineisabletoprocess,itwillendupinhugeWIP,thusaffectingthecompleteflow.
4.Balancing
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Evenifthelineisloadedbasedonthecapacity,thereisachanceofincreasedWIPinthe
lineduetounbalancedproduction.
Thismayhappenduetoabsenteeism,laborturnover,changeinstyle,badcutting,etc.
Based on the inventory level data in each work station, the line can be balanced using
utilityoperators,throughrequiredoperatortransfersandovertime.
5.Cutflowcontrol
To control WIP, the cycle times are to be kept low by following FIFO procedure for every
cut.
Thiscanbeensuredbyutilizingcuttrackingsheetandbundletrackingsheet.
WhyIndustrialEngineeringisNeedinApparelIndustry?
Industrial way of garment production needs a thorough preparation of production because in the
same time, it is necessary to combine a few factors: people, time, machines and place of
production,organizationandmaterialinacoordinatedandrationalsystem.Technologicalsystem
of garment production must enable expected quality of product, necessary scope of production,
deliveryofreadymadegarmentsintheexpectedtime,maximumuseofcapacitywith minimum
expenses. An Industrial Engineer can perform several activities to fulfill their task, Processes
andProceduresofmanufacturingorserviceactivitiescanbeexaminedthrough
Process Analysis. Industrial engineers can use Work Study comprehending Method Study and
TimeStudy.ThementionedactivitiesarealsocalledoperationsManagement.Furthermorecan
Industrial Engineering involve inventory management to make a manufacturing process more
feasible and efficient . Industrial Engineers used to increase efficiencies and costeffectiveness
of operations by the products strategies like Highvolume production, longruns and minimal
variations.
Conclusion:
ThisconceptofIndustrialEngineeringisakeytoapparelindustry to improve their work nature
andthemethods.Theapparelindustryisidentifiedasabuyerdrivenorcustomerdrivenindustry,
so the apparel production has become more intensified by global competition. To survive in this
competitiveworldtheindustryshouldworkmoreefficient.Theconceptswhichare outlined here
are the most important factors to improve the productivity and efficiency of the industry. The
applicationofindustrialengineeringmethodlikemethodengineering,workstudy,capacitystudy,
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line plan and other operations management systems are ultimately leads the industry to timely
deliveryofgoods,highprofitanddeveloptheworkingenvironmentasahappyplace.
References:
1.IndustrialengineeringinapparelproductionbyVRameshBabu
2.http://www.docstoc.com/docs/72143811/IndustrialEngineeringforApparelIndustryPDF
3.http://www.scribd.com
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AbouttheEditorinChief
Mazharul Islam Kiron is a textile consultant and researcher on online
businesspromotion.HeisworkingwithoneEuropeantextilemachinery
company.HeisalsoacontributorofWikipedia.
FindhimonLinkedIn@MazharulIslamKiron
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3Comments
Sortby Oldest
Addacomment...
ShafaquatHussainAligarh
hellocanucalmeimshafaquathussainfromindia...098730754076
LikeReplyMay13,20151:10pm
SuvasreeMajumderJuniorDesigneratZxyInternational
CanupleaseelaborateonSAMcalculation?Andhowmanyminutesare
requiredfordifferentprocedures?
LikeReplyJul12,20153:32am
WooluruYerriswamy
ifoundgoodmaterialrelatedtogarmentindustrywithrespecttoindustrial
engineering.
LikeReplyJun14,20164:50am
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