Short description why industrial engineering is important for RMG sector in Bangladesh.

1. Postgraduate Diploma in Knitwear Industry Management, PGD-KIM
BRAC Institute of Governance and Development (BIGD) BRAC University
IMPORTANCE OF INDUSTRIAL ENGINEERING
DEPARTMENT IN RMG SECTOR
PGD-KIM
Md. Majharul Islam 9/27/19 KIM-103

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Prepared by:
Mohammad Majharul Islam
PGD-KIM, Brac University
Intake: 03, Batch: 05
Section: A, ID: 19381027
Submitted to:
Dr. Shanawez Hossain
Assistant Professor and
Director EDC, BIGD BRACU
Submission Date:
27 September 2019

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Acknowledgement
I would like to express my special thanks of gratitude to my faculty teacher Dr. Shanawez
Hossain, Assistant Professor and Director EDC, BIGD BRACU, who gave me the golden
opportunity to do this wonderful research on the topic “Importance of Industrial Engineering
Department”.
As an IE professional it was my pleasure to do a research on which is related with me. During
this research project I’ve learn so many new things when go deep regarding the topic. To get
the related information I’ve go for detail in Industrial Engineering books & related information
from different sources, which have widen my knowledge as well.
Secondly I would also like to thank my senior Mr. Prabhakar Guta Rauniyar, Sr. Manager-IE
and N.L Chandana, GM-IE of Esquire Knit Composite ltd. who helped me a lot in by giving
several information & guidance during this research to complete it within the time limit.
Overall it helped me to increase my knowledge and skills.

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Overall goal of the study
Industrial Engineering concept is built to run an industry with the implementation of
engineering method by calculative way to get the maximum output from the existing
resources. The goal of the study is to understanding of the importance of Industrial
Engineering Department in RMG sector of Bangladesh which is the largest sector of earning
economy for our country. To accelerate development of the economy & our RMG sector
economic sustainability IED can be the key factor. And by this study we can identify how it
can be.
Reasons for the current study
In recent days the market of RMG is very competitive and risky. It is very difficult to survive in
this market with this serious competitions. With the increases of wages of the workers, the
situation is getting harder. Many of the garment industries are closed in recent few months.
With the maximum utilization of resources and working smartly with new technique &
methods with minimizes of wastage it is possible to survive in the market. This process is done
by the Industrial Engineering Department. To identify the importance of the Industrial
Engineering Department is the main goal of the study.

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Objectives
The main objective is to find out and understandable the importance of IED in RMG sector in
Bangladesh. Main key objectives are as follows:
 What is Industrial Engineering Department
 Why it is important
 How Industrial Engineering Department works
 What is the benefit or output having IE practice
Research Questions
 What is Industrial Engineering Department
 What is their roles & responsibilities
 What is their working procedure
 How maximum utilization can be done
 How the productivity & efficiency can be improved
 How to develop a skilled workforce
 Which new technologies are suitable for out RMG sector
 How we can create a standard working environment
 Overall how we can survive & run business with a good profit

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Table of Contents
Acknowledgement
Overall goal of the study
Reasons for current study
Objective
Research questions
1. Introduction....................................................................................................................................6
2. Concept of Production & Productivity...........................................................................................6
2.1 Production:....................................................................................................................................6
2.2 Productivity:..................................................................................................................................7
3. What is Industrial Engineering?.....................................................................................................7
4. Role of Industrial Engineering Department...................................................................................7
5. Methodology & Working process of IED .......................................................................................8
4.1 Pre-production:.............................................................................................................................8
4.2 Operation:.....................................................................................................................................8
4.2.1 Preparing machine layout:.....................................................................................................9
4.2.2 Operator training: ..................................................................................................................9
4.2.3 Pre-planning for line feeding: ................................................................................................9
4.2.4 Arrange workplace:................................................................................................................9
4.2.5 Capacity study & Line balancing: .........................................................................................10
4.2.6 Production study of different workstation: .........................................................................10
4.2.7 Train-up Production staff:....................................................................................................10
4.2.8 5S implementation:..............................................................................................................10
4.2.9 Preparing different reports:.................................................................................................11
6. Benefit of Having IED in RMG sector:..........................................................................................13
7. Conclusion: ...................................................................................................................................13
8. Significance of the study:.............................................................................................................14
9. References:...................................................................................................................................14

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1. Introduction
Garment Business today becomes very competitive. Low price, less lead time, high costing,
many competitors made the market saturated. Depending on the level of journey, this
business came to a professional and scientific stage, where accurate planning, proper time
management in production and operation, high skilled technical support, optimum cost-profit
estimation are very important issues to survive. Now a day's, it is impossible to run a garment
manufacturing operation without scientific and professional approach. Industrial Engineering
concepts are developed on this demand. Industrial Engineering concepts are required in every
stage including Costing, Product R&D, Planning, Supply Chain, Production Management,
Maintenance Management, Layout plan, Productivity Improvement, Cutting Improvement,
and Manpower Skill Development and so on. Every Garment Owner now understands that
only scientific and professional approach can make the profit.
2. Concept of Production & Productivity
2.1 Production:
Production is any progress or procedure developed to transform a set of input elements like
men, machinery, capital, information and energy into a set of output elements like finished
products and services in proper quality and quantity, thus achieving the objectives of an
enterprise (Buffa and Sarin, 2009).
Production system

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2.2 Productivity:
Productivity may be defined as the ratio between output of wealth and input of resources of
production. Output means the quantity produced and inputs are the various resources
employed, e.g., land, building, machinery, materials and labor.
Productivity refers to the efficiency of the production system. It is an indicator of how well
the factors of production (land, capital, labor and energy) are utilized (Glock and Kunz, 2009).
Productivity =
𝐼𝑛𝑝𝑢𝑡
𝑂𝑢𝑡𝑝𝑢𝑡
3. What is Industrial Engineering?
Industrial Engineering is the application of engineering method to get optimum output using
the existing facilities of integrated systems consists of people, materials, information,
equipment, energy and technology.
4. Role of Industrial Engineering Department
 Enhance productivity
 Reduce costs
 Standardize & simplify the processes
 Analyze risk factors
 Enhance Quality
 Eliminate the waste
 Optimize the utilization of resources.
 Make work environment friendly

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5. Methodology & Working process of IED
There are 2 segments of IE Department.
 Pre-production
 Operation
4.1 Pre-production:
Flow chart of pre-production IE working process:
4.2 Operation:
The IE team in operation perform the activities as follows:
 Preparing machine layout.
 Operators training.
 Pre planning for line feeding.
 Arrange workplace.
 Capacity study & line balancing.
 Production study in different workstation (Where necessary).
 Train production staffs.
 Monitoring ongoing production.
 5S implementation
 Different report making for management. (I.e. WIP report, Efficiency report, NPT
report, skill inventory etc.)
Analyze
garment &
making
operation
breakdown
Workout the
SMV
SMV saving
Method &
operation
standardization

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4.2.1 Preparing machine layout:
The sewing line layout can be defined as the way sewing workstations are placed in the sewing
floor to form a line (or batch) that works on single style. The purpose of choosing one line
layout over other is to achieve best production with existing resources.
There are different types of line layout:
 Line with center table and operators facing same direction
 Line with center table and operators facing opposite direction
 Straight line without center table and one raw of machines
 Side by side machine layout
 U-shaped line layout
 Modular line layout
 Machine layout in UPS system
4.2.2 Operator training:
When some unusual process came, operators need to train up for those process to make
them efficient. On the other hand lower graded operator also trained up to upgrade them to
achieve the desired efficiency level & to improve the strength of the sewing floor.
4.2.3 Pre-planning for line feeding:
After getting the line loading plan, IE need to pre-plan for the required thing to arrange on
time. The pre-planning includes:
 Required types & quantity of machine
 Skilled operator to perform the task
 All types of attachment & folder required
 Sample analysis etc.
4.2.4 Arrange workplace:
After having all necessary things and paper layout, workplace need to arrange for every task
according to m/c layout to get the maximum efficiency of that task.

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4.2.5 Capacity study & Line balancing:
Capacity study: This is the most common technique used by an engineer to set targets. It
helps in setting and developing standards in terms of allowed time to produce a certain
number of units in a normal workday.
Line balancing: Line Balancing is leveling the workload across all processes in a cell or value
stream to remove bottlenecks and excess capacity. A constraint slows the process down and
results if waiting for downstream operations and excess capacity results in waiting and
absorption of fixed costs. It is the allocation of sewing machine, according to style and design
of the garments. It depends on what types of garments we have to produce. It is done to
increasing productivity.
4.2.6 Production study of different workstation:
This task is done to identify the bottleneck cause. If there are any workplace from where
desired output not get, production study need to perform on that area to identify the
problem. After the study action is taken to solve the problem.
4.2.7 Train-up Production staff:
To get the desired efficiency & productivity production stuff need to be very smart & well educated.
To make them pro-active & task oriented they should be trained up. And this task is done by IED
primarily.
4.2.8 5S implementation:
5S is one of the first tools that can be applied in a company that is starting down the path of
the continuous improvement culture. A 5S implementation helps to define the first rules to
eliminate waste and maintain an efficient, safe, and clean work environment
Sort: Separate required tools, materials, and instructions from those that are not needed.
Remove everything that is not necessary from the work area.
Set in order: Sort and organize all tools, equipment, files, data, material, and resources for
quick, easy location, and use. Label all storage locations, tools, and equipment.

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Shine: Set new standards for cleanliness. Clean and remove all trash, grease, and dirt.
Everything must be clean, tidy, and neatly put in its appropriate place. Cleanliness provides a
safe workplace—and makes potential problems noticeable, e.g., equipment leaks, loose
parts, missing guards, loose paperwork, or materials.
Standardize: Engage the workforce to systematically perform steps 1, 2, and 3 above daily, to
maintain the workplace in perfect condition as a standard process. Establish schedules and
set expectations for adherence.
Sustain: Make 5S part of your culture, and incorporate it into the corporate philosophy. Build
organizational commitment so that 5S becomes one of your organizational values so that
everyone develops 5S as a habit. Integrate the 5S methodology into the performance
management system.
Before 5S implementation After 5S implementation
4.2.9 Preparing different reports:
To keep records, documentation, visualizing the problems & benefit different reports need
to prepare on daily, weekly, monthly & yearly. Some reports as follows:
 Capacity hit rate
 Efficiency report
 Work in progress (WIP) report
 Not productive time(NPT) report
 Skill Matrix etc.

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Examples of some reports:
NPT Report WIP report
Efficiency report Capacity Hit rate report

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6. Benefit of Having IED in RMG sector:
Existing of Industrial Engineering there are a vast benefit. Some are as follows:
 Increasing productivity
 Achieving the benchmark efficiency
 Reduce the wastage of resources.
 Producing skilled workforce
 Maintaining standard & systematic working process
 Finding the scope of improvement
 Visualization of profit reducing area
 Implementation of new technologies feasible for the organization
 Very discipline & friendly working environment
 Ensuring the highest utilization of resources.
7. Conclusion:
This concept of Industrial Engineering is a key to RMG industries to improve their work
nature and the methods. The apparel industry is identified as a buyer-driven or customer
driven industry, so the apparel production has become more intensified by global
competition. To survive in this competitive world the industry should work more efficient.
The concepts which are outlined here are the most important factors to improve the
productivity and efficiency of the industry. The application of industrial engineering method
like method engineering, work study, capacity study, line plan and other operations
management systems are ultimately leads the industry to timely delivery of goods, high profit
and develop the working environment as a happy place.

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8. Significance of the study:
After this study we come to know that IED working area is vast with improving efficiency,
productivity, lower the costs, reduces the wastages, improving the skills of workforce, easy &
cleanliness, making friendly working environment and so on. With the practice of IE tolls &
technique an organization can achieve a good margin of profit with the same resource. Which
is the most important of us in this highly competitive market and to get our economic
sustainability.
9. References:
i. Handbook of Industrial Engineering of apparel production, V Ramesh Babu, 2011
ii. Handbook of Industrial and Systems Engineering, Adedeji Badiru, 2015
iii. Industrial Engineering Department, Esquire Knit composite ltd.
iv. https://textilelearner.blogspot.com
v. https://www.onlineclothingstudy.com
vi. https://www.simplilearn.com
vii. https://en.wikipedia.org