IE Methods Improve Factory Efficiency

What is IE ?
Are you Know?
Comfortable
Prepared by Shamim Hasan

Convention Program
1. Technical / IE feedback to production floor from
development section is not available (like;
folder, method, production instruction etc..)
2. Target sample rewiring next to start
3. Primary IE activity implement at factory wise
coordination with factory management
4. Knowledge shearing within the team who have
best practice in factory doing
5. Attend the PP meeting internal and with buyer
responsibility IE activity

IE Related
What is IE
Function of IE Department
Responsibilities of IE
IE DEPARTMENT-WORK PROCESS FLOW
Sewing process method improvement
Capacity Analysis
Balancing
Efficiency Game

Industrial engineers determine the most effective ways to use the basic
factors of production—people, machines, materials, information, and
energy—to make a quantity and quality product.
Industrial Engineer is a logical way to find out:
a) The best way to do something
b) The time required to do it
c) The way to measure the result
3 logics of
IE
Is the way of doing correct method?
What is the time require?
How to improved?
Industrial engineers determine the most effective ways to use
the basic factors of production—people, machines, materials,
information, and energy—to make a quantity and quality
product.
What is IE?

FUNCTION OF IE DEPARTMENT
Work study
The systematic examination
of the methods of carrying
on activities so as to improve
the effective use of
resources and setup
standards of performance
for the activities being
carried out.
WORK
STUDY
METHOD STUDY
To simplify the job and
develop more economical
methods of doing it
WORK MEASUREMENT
To determine how long it
should take to carry out
HIGHER
PRODUCTIVITY

FUNCTION OF IE DEPARTMENT
IE DEPARTMENT
Pre Production Activates Production Activates
Cost Engineering Production Engineering
Production
Follow Up
Production
Place
Development

IE DEPARTMENT-WORK PROCESS FLOW ( Per Production Activates)
NEW SAMPLE OR SKETCHS
IE DEPT
Bulletin make
Man, MC requirement & Production Target
Folder Gauge
Foot and attachment
Needle type
Thread consumption
Thread Tex or Count
Placement of thread
Total meter of thread
HOGO
Merchandising Dept
Maintenance Dept
Lay out make
Final MC requirement
Line Balance
Man Power allocation
CPU operation allocation (Critical Path Unit)
Technical Dept

Line Feeding
TECHNICAL/MAINTENANCE/IE
QUALITY-TEAM REQUIRED
START RECORD HOURLY PRDN
MONITOR CRITICAL AREA
CHECK OPRATOR HANDLING (MOTION STUDY & METHOD S
WORK PLACE ENGINEERING ( FOR MOTION REDUCE)
PRODUCTION STUDY
CAPACITY STUDY
TIME STUDY
MOCKUP EVERY OPERATION
Line Manager
Follow up
Bottleneck ProductivityCapacity Efficiency
Line Supervisor
IE DEPARTMENT-WORK PROCESS FLOW ( Production Activates)
CASE STUDY

1. What kind of operation we needed for that design is described.
2. What type of machine we will use for that product.
3. How many operator we needed for that product.
4. How many workstations are allocated for this style?
5. What type of stitch we needed for that style.
6. What kind of guide or pressure foots need for particular operation.
7. What will be the target of the style?
8. What efficiency we will consider of this style.
9. Set target for the individual operator for each operation.
10. Set balancing operation wise with main process to sub process.
Prepare the Operation bulletin:

H & M Production Office
Operation Bulletin
Style - James 5 pkt O/D Pant Twill DISCP CPU ASM 1 ASM 2 TOTAL TGT 100% 1609 Catogary Required
SMV ( M ) 4.84 9.11 7.18 21.13 PLANED TGT 880
SMV ( H ) 1.43 2.17 1.93 5.53 PLANED EFF% 55% Operators 54
M/C 14.50 22.00 17.50 54.0 WORKN HR 600 Helpers 15
HLP 3.00 5.50 6.00 14.5 PCS/MAN PW 12.31 Ironers 3
IRON 2.00 1.00 3.0 1st Total 72
MAN PW 19.50 28.50 23.50 71.5 DATE 27-Dec
W/STN ( M ) 21 34 23 78.0 26.66
Serl
No
Zone Section Operation Description H/Mc Machine name S.M.V
Operator
Req
Alotd
Plnd.
W/S
TGT /
Hrs
Presser
Foots
Folder
Attachmen
t & Gauges
Remarks
1 CPU Loops making (5) M FL 0.18 0.26 0.50 1.0 333 3/8" folder for 2 lines
2 CPU Loops cut and make bundle M VC 0.32 0.47 1.0 1.0 188
3 CPU W/B Twill tape att to w/b inner part M SN 0.50 0.73 1.0 1.0 120 folder
4 CPU Top part attach to w/b inner part M SN 0.32 0.47 1.0 1.0 188 folder Mc guide
5 CPU W/b 1/16" t/s at top part M SN 0.56 0.82 1.5 2.0 107 CR-1/16"
6 CPU W/b cut and make bundle H Plain Table 0.28 0.41 1.0 1.0 214
7 CPU Coin pkt Coin pkt hem M SN 0.18 0.26 0.5 1.0 333 1/4" floder
8 CPU Marking for coin pkt attach H Plain Table 0.20 0.29 1.0 1.0 300 pattern
9 CPU Coin pkt fold & attach to facing M SN 0.25 0.37 1.0 1.0 240
10 CPU Coin pkt decoration stitch M SN 0.36 0.53 1.0 1.0 167 CR-1/14"
Help to
facing att
11 CPU Facing Up & down Facing att marking H Plain Table 0.30 0.44 1.0 1.0 200
12 CPU Up & down Facing attach to pkt bag M SN 0.68 1.00 2.0 2.0 88
13 CPU Fly S. fly inner part tack and mark for eyelet holeM SN 0.28 0.41 1.0 1.0 214
14 CPU Make eyelet hole (3) at inner s.fly M EL 0.27 0.40 1.0 1.0 222 P/F Mc guide
15 CPU Back pkt Back pkt hem M SN 0.32 0.47 1.0 1.0 188 1/2" gause
Revision
Description: Loops making with F/L, S.fly
inner side Button, Double part w/b and 3
rows t/s (top 1 and down 2). Back pkt inner
part reinforcement. Back pkt serging all
area with two part.
TOTAL SMV
Mens-pant -S-06

Find out the necessary attachments:
It is mentioned what kind of attachment we can use for better
production.
1. Here it is mentioned what kind of foots we will use.
2. What kind of gauges we will use or need to be use.
3. What kind of guide we needed for that operation and have
ensured it.
For Example:
P718 Right Guide Edge Foot use for ditch in stitch operation

P713 Shirring Foot use for ladies item
P731 Adjustable Guide use for margin stitch

Find out the necessary work aids:
To do work we need some supporting equipment's that can makes the
operation flexible that are the work aids. IE dept. has to find out and be
ensured that using into the working place.

Though the time study and motion study are the most
common function of Industrial engineer, They have some
other important responsibilities as well:
Capacity analysis of the factory
Capacity Balance analysis- Cutting – sewing – washing –
finishing.
Production control system.
Factory decoration and efficient layout plan
Implement new method for improving efficiency.
Implement PIB system for the workers.
Operator training
Operator recruitment and skill judgment.
Evaluate new and existing operator grading judgment.
Monitoring and improve the operator performance
Create multi skill operator & follow up
Responsibilities of IE:

Prepare the sewing line layout.:
IE must prepare the machine layout according to the garments operation
wise, this is very important for production flow system. On that basis
garments will move, A proper organize layout will reduce the TPT (Through
Put Time) of production and increase the higher productivity.
For Example:

Industrial Engineering dept. will ensure the capacity of the operator ,
capacity of the sewing line and capacity of the factory. The below
shows format.
Factory Capacity : Total minutes produce/ Factory available minutes

Using template for easy way to turning front pocket bag . Here
Operator feels comfortable and doing maximum output.
The below shows some photograph for better
understanding:

Previous method:
Front pocket facing
attach without tools
Present method: We use IE tools
(Tray) and make the operation easy,
proper organize and increase
operators efficiency.

Previous method: We use
Helper for Hook & Bar
attach marking
Present method: We use Laser light
for Hook & Bar attach point. Here we
remove marking, reduce helper and
increase better quality product as
well as efficiency.

Previous method: We use Helper with pattern for loops Bar tuck
position mark and loops inlay folding area.

Present method: We use Laser light for loops Bar tuck and makes
loops position straight.

By the definition of the word, balancing is equality.
Process Balancing means, balance the capacity equally at
the sub processes in the main process
Get the maximum out put from the process flow
Proper utilize the manpower
Reduce the waiting time of the workers
Pitch time: In industrial Engineering, Pitch time is a ratio of total SMV of
garment and number of operations to be set for the style. Or
Pitch Time = Garment SMV/No. of operations.
=4.9/8
=0.61 min
Pitch time = Balanced work time for 1 work station
Balancing:
Benefit of Balancing:

Defining Productivity:
The definition of PRODUCTIVITY is given as “OUPUT” compared to
“INPUT”.
In the case of a factory, “output” can be taken as the
number of products manufactured.
while “input” is the people, machinery and factory
resources required to create those products within a
given time frame.
Defining Standard Time:
Standard Time (also referred to as the “Standard Minute Value” or
“SMV”), is the time required for a qualified worker working at
“Standard Performance” to perform a given task. The SMV includes
additional allowances for Rest and Relaxation, Machine Delay and
anticipated Possibilities.

To calculate SMV, First of all we must find out BM (Basic Minutes)
Now BM= ASCT X Operator Rating ASCT = Average
Single Cycle Time
ASCT X 90/100
ASCT of W/b join
operation by SNLS
=0.85
=
0.85 X 0.90=
=
SMV= BM X (100 + MD + PFD + BHT)/100
= BM X (100/100 + MD/100 + PFD/100 + BHT/100)
Allowance:
MD- Machine delay 10% for SNLS
mc
PFD- Personal fatigue & delay 7.5%
BHT-Bundle handling time 2% to 5%
depends on the fabric characteristic
= 0.77 X (1+0.1+0.075+0.02)
= 0.77 X 1.195
=.91
Pcs Per hr.= 60/.91 =66
It is a numerical value which is represented the standard time of a process
or operation in a standard environment for standard worker.

Total working hr. X DL X Line Efficiency
Product SMV
=
=
24.5
600 X 80 X .65
= 1273 pcs / Day

SMV produce
CT X DL
X 100=
Increase production:
Basic pant SMV=24.5
Out put=1300 pcs
CT=Clock time=600 min
DL=Direct labor=80
SMV= Standard Minutes
Value
24.5 X 1300
600 X 80
X 100=
= 66.35%
By increasing productivity, reduce manpower or reduce overtime we can
improved efficiency.
The above calculation shows we just increase production /hour 10 pcs and
improved efficiency (66.35 - 61.25) = 5.10%
Output Efficiency
Output Efficiency Prepared by Shamim Hasan

SMV produce
CT X DL
X 100
SMV X Out put
CT X DL
=
=
Reduce Manpower:
Basic pant SMV=24.5
Out put=1200 pcs
DL=Direct labor=70
SMV= Standard Minutes Value
24.5 X 1200
600 X 70
X 100=
70%=
X 100
Reduce Overtime:
Basic pant SMV=24.5
Out put=1200 pcs
DL=Direct labor=80
SMV= Standard Minutes Value
SMV produce
CT X DL
X 100
SMV X Out put
CT X DL
X 100
=
=
24.5 X 1200
540 X 80
X 100=
68%=
The above calculation shows we just
reduce 10 people and improved
efficiency (70 - 61.25) = 8.75%
The above calculation shows we just
reduce 1 hour overtime and improved
efficiency (68 - 61.25) = 6.75%

Where do most industrial engineers work?
Manufacturing firms and service industries hire a significant number of
IEs. Today, more and more businesses hire IEs in areas like sales and
marketing, finance, information systems, and personnel.
Other industries employing IEs are hospitals, airlines, banks, railroads,
and social services.
What skills do industrial engineers need?
Industrial engineers should also possess the following specific qualities:
Creativity
Critical-thinking skills.
Listening skills
Math skills
Problem-solving skills
Speaking skills
Writing skills
How do industrial engineers benefit society?
Benefits that can be linked directly to the work of industrial engineers include:
Leaner, more efficient, and more profitable business practices while increasing
customer service and quality. Improved efficiency. This improves competitiveness,
profitability, and reduces resource requirements.

Think you ?
Are you need IE
concept your
life.

IE Methods Improve Factory Efficiency

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