At present Industrial Engineering (IE) is one of the important department for each garments or textile factory. Today’s maximum factory is run by industrial engineers, where they have to follow a process flow chart. By which they can easily control the whole garments production processes....

1. Role of IE
In Garments Industries of Bangladesh
Ariful Islam
Dept. of Industrial and Production Engineering
Jessore University of Science and Technology

2. Introduction:
At present Industrial Engineering (IE) is one of the important department
for each garments or textile factory. Today’s maximum factory is run by
industrial engineers, where they have to follow a process flow chart. By
which they can easily control the whole garments production processes

3. Process Flow Chart of Industrial
Engineering (IE):
Negotiation with garments merchandiser
↓
Garments analysis
↓
Make P.P meeting if all the required fabrics, trimmings and
accessories are in housed
↓
Production target
↓
Set machine layout
↓
Line setting
↓
Line balancing
↓
Continuous production meeting
↓
Collecting production data
↓
Preparing production report
↓
Production report analysis
↓
Report submit to factory manager

4. IE (industrial Engineering)
 IE (Industrial Engineering) Department, is a department that has a
function and responsibility to measure, analyze, solve problems given
in terms of efficiency, productivity, health, work safety, etc. within
the scope of work discipline in order to spur growth and healthy
corporate production and balanced. Fundamental question for an IE is
what (what) and how (how). What (what) is a manifestation of the
question of what issues are facing or what issues arise in relation to
production. Meanwhile, how (how), is a solution (solve problems) of
the questions or problems existing production. Accuracy / validity of
data and the accuracy of the analysis will determine IE solve
problems.

5. What do IEs do?
 Industrial Engineers work to make things better ,be they processes,
products or systems.
 Typical focus areas include:
– Project Management
– Manufacturing, Production and Distribution
– Supply Chain Management
– Productivity, Methods and Process Engineering
– Quality Measurement and Improvement
– Program Management
– Ergonomics/Human Factors
– Technology Development and Transfer
– Strategic Planning
– Management of Change
– Financial Engineering

6. Responsibilities of IE:
 Planning layouts
 Monitoring Production flow system
 Deicide the machines and attachments for all style
 Pay system
 Monitoring and improve the operator performance
 Operator training
 Production control system
 Quality control
 Others

7. Role of IE
1. Operation break down
2. Design machine layout
3. Calculate the SMV
4. Time study
5. Eliminate excess hand motion from operation
6. Balance the line
7. Allocate the man power
8. Create operation bulletin
9. Calculate productivity
10. Skill inventory
11. Value stream mapping
12. Lean the kaizen event

8. Operation break down
 The method of preparing operations' list in a sequence is called as operation
breakdown.
 The sheet of listed operations of a style is also known as operation breakdown.

9. Design machine layout
 there are multiple options of sewing line layout to choose from, most
garment manufacturers are comfortable with straight lines having center
table in between two rows of machines.

10. Time study
 Time study help to define how much time is necessary for an operator to
carry out the task at a defined rate of performance.
 Time Study Tools
A stop watch
Time study format
One pen or pencil
Time Study board

11. Eliminate excess hand motion from operation
 Pareto your inventory
 Reduce replenishment lead times
 Revise order cycles/quantities
 Improve your forecasting
 Eliminate obsolete stock
 Centralize your inventory
 Lower your service level
 Reduce variability of demand and supply
 Align your metrics

12. Balance the line
 Line balance means the better allocation of the necessary tasks between
the operators, which reduces waiting time.
 For line balance we have to know some data and some calculating
information those are as follows: -
How many operators.
Operation.
SMV
Performance.
Potential production / hour.
Hours to achieve target.
Capacity.
Target.

13. Allocate the man power
 Manpower Allocation is an important process that:
(1) enables organizations to determine the most efficient manpower
composition, and
(2) provides a foundation to recruit and/or reorganize the manpower to
achieve organizational goals. An effective manpower plan has the right number
of workers with the right skills for the right tasks at the right time

14. Create operation bulletin
 An operation bulletin is one of the primary IE tools. An OB helps to set a production line
with correct number of machines and manpower.
 A basic operation bulletin contains following information.
Daily working hours ;
Target output per day or per hour
Total SMV (Sewing SMV and Non-sewing SMV)
OB prepared by (Name of the Engineer)
Job code
Operation description
Machine description
Calculated production per hour
Name of the Folder and attachment if used
Calculated no. of machines
Actual no. of machines
Machine summary list

15. productivity
 Productivity is an economic term describing the relationship between outputs
as compared to inputs needed to produce those outputs.It measures the
efficiency of a company's production process.

16. Skill inventory
Skill Matrix is a chart or a database where operator’s past performances on
various operations are recorded in a systematic way for the future reference. In
a skill matrix operator performance is recorded in efficiency percentage.
Skill matrix is also called as skill inventory of the operators

17. Value stream mapping
Value stream mapping is a lean-management method for analyzing the current
state and designing a future state for the series of events that take a product or
service from its beginning through to the customer.
At Toyota, it is known as "material and information flow mapping".

18. Lean the kaizen event
 A Kaizen Event is an action that is deployed in order to improve processes.
Kaizen, specifically, is the exercise of continuous improvement