Industrial Engineering Tools & Activities of a RMG !!!

Presentation on
What is IE & Activities of IE in Medlar Apparels Ltd.
Prepared by,
Imdadul Haque Likhon (Sr. IE)
Mahibur Rahman (IE)
KEEP CALM AND LOVE AN
INDUSTRIAL ENGINEER

Industrial Engineering Department
KEEP CALM AND LOVE AN INDUSTRIAL ENGINEER

History of Industrial Engineering
 Henley was the first practioner of IE. He was a
farmer who make simple observations about
farming methods and ways of improving them.

WHAT IS IE
 Industrial Engineering is a branch of engineering which
deals with optimization of complex process or systems. It
is concerned with the development, improvement,
implementation and evaluation of integrated
manufacturing system of people, money, knowledge,
information, equipment, energy, materials with the
principles and methods of engineering design to
specify, predict and evaluate the results to be obtained
from such system and process.

Present Situation of
Manufacturer
Price
Cost
BEP
Profit Loss
Today I
am here

NECESSITY OF IE DEPARTMENT IN
GARMENTS SECTOR
1. Enhancing productivity
2. Process standardization
3. Operation analysis
4. Workplace design
5. Work measurement/Set up standard time of each
process
6. Proper utilization of man machine & materials
7. Calculating efficiency
8. Man Machine planning

Uses of Industrial Engineering
1. Analyses and improve the existing systems for higher productivity.
2. Issue Standard times (SMV) for each operations
3. Garment cost of manufacture [CM] calculation based on standard times.
4. Production planning and control (PPC).
5. Control & reduce manpower through proper line balancing & increase
the efficiency of the line.
. Control over time (OT pie chart ).
. Set up target and monitor to achieve in the lines.
8. Evaluate Operator Skills during the recruitment, grading, new style
feeding.
2. Make reports, about factory status, Monthly, Daily ….
. Improve operator sewing skills as well as perfect handling.
0. Analyze and update key productivity indicators (KPI).
3. Implement & maintain new systems
4. Output step up through work place engineering.
1. Work out & maintain proper incentive schemes
KEEP CALM AND LOVE AN INDUSTRIAL ENGINEERKEEP CALM AND LOVE AN INDUSTRIAL ENGINEER

PRESENT ACTIVITIES OF IE IN MEDLAR
1. Process standardize
2. Evaluating correct SMV
3. Thread consumption of different style
4. Making bulletin & layout
5. Making efficiency report
6. Daily target setup
7. Method & Motion study
8. Making skill inventory & grading
9. Daily line balancing by capacity study and SMV
10. Bottleneck process monitoring & line balancing
11. Recording non productive time
12. Style wise machine planning and rented m/c monitoring
13. Increase operator capacity by one hour capacity study
14. Skill wise manpower recruiting

PRESENT ACTIVITIES OF IE IN MEDLAR
16. Daily all types of material tracking
17. Size set monitoring
18. Attend PP meeting
18. Follow up PP meeting comments to ensure quality
19. CAD efficiency follow up

Daily Man-Machine Status
By using this man-
machine status we
can calculate total
running machine;
idle m/c; present
O/P, H/P & I/M;
rented m/c; lended
m/c; absenteeism
%; uses O/P+I/M to
H/P number of the
day.

Daily Line Target
We give the line
target considering
day manpower &
other factor.

Daily & Monthly Efficiency Report
To identify the
line/floor/factory
performance it
one of the core
report. About this
report, we will
discuss in below:

Efficiency Formula
To calculating efficiency:

1) Efficiency % = Produced minutes x 100
Utilized minutes
Produced minutes = Qty. produced x time allowed per unit
(Output) (SMV)
Utilized minutes = Manpower x worked minutes
2) Performance %= Achieved production x 100
Target production(100%)

Efficiency Example
 Line- 1
* SMV of Garment = 16 minutes
* No of workers in line = 60
* Working hours = 9
* Line Output = 1000 Pcs
Output (1000) x SMV (16)_____ %
No of workers(60) X Working Minutes (540)
Line Efficiency = 49%
 Line- 2
* SMV of Garment = 16 minutes
* No of workers in line = 80
* Working hours = 10
* Line Output = 1300 Pcs
Output (1300) x SMV (16)_____ %
No of workers(80) X Working Minutes (600)
Line Efficiency = 43%
THEREFORE: LINE 1 IS MORE PRODUCTIVE THAN LINE 2,
ALTHOUGH LINE 2’S PRODUCTION IS HIGHER

Example for Calculating SMV
Observations:
 Observed Cycle Time= 0.80 Minute
 Performance Rating = 80%
Calculations:
 Find Basic Time = 0.80 X 0.80
0.64 Minute
 Decide Allowances = Personal & Fatigue (P&F)- 12%
(Machine Contingencies) - 9%
 Add allowances and calculate SMV
0.64 + 21% = 0.81 Minute
Therefore TGT/hr : 74 Pcs

Key Productivity Indicators (KPI)
 Man- Machine, Direct-Indirect ratio
 Absenteeism, Migration, Late come, Lost time percentage
 Output pcs per man hour, Pcs Per machine, Monthly TTL output
 Efficiency, Performance
 Rejection, Defect percentage
 Cut to ship, Receive to ship ratio
 Normal hour to OT hour percentage
 Marker efficiency
 Overhead cost
 Total salary cost, O.T cost
 Cost per minute (CPM), earn per minute (EPM), CM value/mint

SMV BANK
SMV Bank consists
of SMV of
individual operator
as well as
individual process
which helps to
calculate SMV of a
complete
garment.

Operation Breakdown
From operation
breakdown we
can identify total
process-wise
number of m/c,
efficiency-base
target, operator
allocation, SMV of
that style before
input the sewing
line. It’s also helps
to do proper
planning.

Line Feeding Time Status
This indicates the
time duration of a
sewing line from
1st input to 1st
output of
production.

Capacity Study & Line Balancing
We calculate the
capacity of the
operator to
balance the line,
to get optimum
production from
the line & overall to
increase the
profitability from
sewing line.

Operator Job Card
This helps day to
day follow-up the
operator
performance.

Bottleneck Study
To get the
hidden
production from
the operator
sometimes we
study the
operator for 1
hour. This study
is called
bottleneck
study.

Q.I Recruitment Test
We take a written
test to get the
Quality Inspector. A
quality full Q.I can
help you to get a
quality full product.

Daily & Monthly DHU Report
DHU means Defects
Hundred Per Unit.
To know the unit-
wise defect%, it is so
much helpful. It is
also buyer
requirement.

Skill Matrix
Skill matrix is used
to know the skill of
an operator.

Worker Evaluation
We also evaluate workers’ performance

Cut Panel Check Status
To know the
wastage fabric%
in cutting
department we
use cut panel
check status.

Learning Curve
To know the pick
time of a line this
is important one.
Let,
1st
Input:
01/15/2015, 08:00 AM
1st
Output:
01/17/2015, 08:00 AM
Feeding Time: 16 hrs.

Data Analysis
We analyze the
line performance
by using modern
graphical view.
It’s also one step
of motivation.

Skill Test Report of New O/P, I/M
Skill test of new
operator & iron-
man is perform by
us.

Thread Consumption
We calculate the
thread consumption
of different style.

NPT Time Follow-up
For smooth production we
follow-up the Non-Productive
Time (NPT) of the line.

Daily Oil Releasing M/C Status
To identify the oil
releasing m/c we
prepare a report on
daily-basis.

Operator Training & Counselling

Backward Planning Follow-up
To ensure time
line feeding we
follow-up the
backward
planning of the
sewing line.

Helper Minimization
We have a
project to reduce
the helper
number from
different style.

Root Cause Analysis
We use fishbone
diagram to solve
& preventive
action plan for
different defect/
problem.

Factory Performance Overview
We present the
factory
performance
overview.

IE NOTICE BOARD
*IE Notice Board is
updated with daily &
monthly status of
sewing floor.
*The Hourly Production
Board consists hourly
sewing production.

FUTURE PLAN OF IE IN MEDLAR
1. Implementing new layout of finishing department
2. Calculating cutting SMV
3. Preparing fabric wastage report
4. Increasing marker efficiency by adding another CAD
package
5. Preparing Gantt Chart

FUTURE PLAN OF IE IN MEDLAR
06. CPM (Cost Per Minute) calculation
07. Per SMV Value
08. SMV-wise CM calculation
09. Implementation of Lean Manufacturing
10. Six Sigma Practice
11. 5-S Implementation in different section

Appendix
 SMV=Basic Time+(Basic Time*Allowance)
 Efficiency=(Earn Minute/Available Minute)*100
Earn Minute= Produced Qty.*SMV
Available Minute= Work Hour*No. of Manpower
 Target=(60/SMV)*Present Manpower*Efficiency
 Factory Capacity=(Work Minutes/SMV)*Total
Worker*Working Day*Efficiency

Appendix
 CPM=(Total Overhead Cost of the Month/No. of SMV
Earners*Work Minute )*Efficiency
 Factory Capacity=(Work Minutes/SMV)*Total
Worker*Working Day*Efficiency

Industrial Engineering Tools & Activities of a RMG !!!

Industrial Engineering Tools & Activities of a RMG !!!

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