what is ie & activities of ie in medlar apparels ltd

Presentation onWhat 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


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 productivity2. Process standardization3. Operation analysis4. Workplace design5. Work measurement/Set up standard time of each

process6. Proper utilization of man machine & materials7. Calculating efficiency8. 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.

6. Control over time (OT pie chart ).7. Set up target and monitor to achieve in the lines.

8. Evaluate Operator Skills during the recruitment, grading, new style feeding.

12. Make reports, about factory status, Monthly, Daily ….

9. Improve operator sewing skills as well as perfect handling. 10. Analyze and update key productivity indicators (KPI).

13. Implement & maintain new systems14. Output step up through work place engineering.

11. Work out & maintain proper incentive schemes

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PRESENT ACTIVITIES OF IE IN MEDLAR


1. Process standardize2. Evaluating correct SMV3. Thread consumption of different style4. Making bulletin & layout5. Making efficiency report6. Daily target setup7. Method & Motion study8. Making skill inventory & grading9. Daily line balancing by capacity study and SMV10. Bottleneck process monitoring & line balancing11. Recording non productive time12. Style wise machine planning and rented m/c

monitoring 13. Increase operator capacity by one hour capacity study14. Skill wise manpower recruiting

PRESENT ACTIVITIES OF IE IN MEDLAR

16. Daily all types of material tracking17. Size set monitoring18. Attend PP meeting18. Follow up PP meeting comments to ensure quality19. CAD efficiency follow up


Daily Man-Machine StatusBy 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 TargetWe 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 FormulaTo 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 SMVObservations:

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 MinuteTherefore 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 Overall productivity

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


Operation BreakdownFrom 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 StatusThis indicates the time duration of a sewing line from 1st input to 1st output of production.


Capacity Study & Line BalancingWe 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 CardThis helps day to day follow-up the operator performance.


Bottleneck StudyTo 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 MatrixSkill matrix is used to know the skill of an operator.


Worker Evaluation

We also evaluate workers’ performance


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


Learning CurveTo 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-upFor 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-upTo ensure time line feeding we follow-up the backward planning of the sewing line.


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


Root Cause AnalysisWe 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 SMV3. Preparing fabric wastage report4. Increasing marker efficiency by adding

another CAD package5. Preparing Gantt Chart


FUTURE PLAN OF IE IN MEDLAR

06.CPM (Cost Per Minute) calculation07.Per SMV Value08.SMV-wise CM calculation09.Implementation of Lean Manufacturing10.Six Sigma Practice11.5-S Implementation in different section


Appendix SMV=Basic Time+(Basic Time*Allowance)


Efficiency=(Earn Minute/Available Minute)*100 Earn Minute= Produced Qty.*SMVAvailable 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