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Industrial Engineering

# What is Industrial Engineering ?

Industrial Engineering is the technique fordeveloping productivity by proper using of

manpower, machine, current

infrastructures & facilities of the factory.

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Definition of Work Study

Work-Study is the critical examination of human works forincreasing productivity.

It is the systematic examination of the methods of carrying outactivities so as to improve the effective use of resources & to

establish standards of performance for those activities.

Another definition of Work Study could be:

A generic term for those techniques, particularly method study andwork measurement, which are used in the examination of humanwork in all its contexts, and which lead systematically to the

investigation of all the factors which affect the efficiency andeconomy of the situation being reviewed, in order to effectimprovement. This has to do with Productivity Improvement, butalso improvement quality .

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Aims of Work Study

To eliminate wastage time and labor.

To reduce fatigue and boredom of work.

To find the best way of doing the job.

To utilize manpower, machineries & materials.

To improve the design of the work place layout.

To standardize the method of work.

To train the operators or its practice as perstandard methods.

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Why Need Work-Study ?

Work study is needed for:Continuous improvement

Method of reduce wastage

Use of resources effectively

Improve the professional life

Exceeding customer expectation

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Method Study

Method study is the systemic recording

and critical examination of existing and

proposed ways of doing work as a means

of developing and applying easier and

more effective methods and reducing cost.

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Purpose of Method Study

To improve work method and procedure.

To determine the best ways of doing work.

To smoothen material flow. To improve layout.

To improve labor efficiency.

To reduce monotony in the work.

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Motion Study

Motion Study is to standardize working motion of themanpower.

PURPOSE:

To determine optimum work

To standardize work

To train operator

To manage operator

Method of analysis

Inspected by listening

By direct observation

By conducting VTD

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Time Study

Time study is very important analysis forfinding SMV.

Condition of time study:

Before making the time study, the workstudy officer ensure that conditions on thejob are normal.

The work flow into the operation is normal.Amount of work in the section is normal.

The size of the work available are normal.

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Techniques of Time study

Assess the performance of the worker.

Understand the flow of work.

Time study person should not disturb theoperators .

Should inform to the operator that he is

going to do sometimes study.Enter every detail on study papers by a

pen as it can not delete.

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Steps In Time Study

Set the correct job method.

Get an operator to use the correct job method.

The operator using time the correct job method.

Sequence the operator by evaluating her skilland effort.

Apply the standard job allowances to allow forthe times when the operator would not be at the

machine sewing.Set the time production quota expected of the

100% (Average ) operator.

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Rating

Rating is the speed assessment of doing work.

Rating = Speed of doing work

Example: Cap & pen adjust by hand.

1. Mr. John can adjust within 4 seconds.

Mr. Johns observed Rating = 90Mr. Johns Rating = obs. Rating / stnd. Rating

=90/100 =0.90

2. Mr. Mill can adjust within 8 seconds.

Mr. Mills observed Rating = 45Mr. Mills Rating = obs. Rating / stnd. Rating

=45/100 =0.45

So, Mr. Johns Rating higher than Mr. Mill.

B kd /Di idi /O ti

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Breakdown/Dividing/Operation

Bulletin

Breakdown is a listing of the content of ajob by elements. A garment consists ofsome parts & some group of operations.

Breakdown means to writing down allparts & all process/operation after oneanother lying with the complete garmentaccording to process sequence. It is a

must to write down the estimated SMV &type of machine beside each & everyprocess.

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Breakdown procedure

APM, Technician Chief & Work-Study officermust sit together to make breakdown.

Technician breaks the garments into parts andgathered the parts one after another by

operation/Process.Then Work-Study officer & APM fix up the SMV

of those operation.

By proceeding this technique when all process

completed need to summarize all process SMVand the total will be called as respectivegarments SMV .

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Layout

Layout means to distribute/allocateelements to the individual operator in theline by considering total worker, worker

experience, total machine, types ofmachine & mainly the estimated SMV ofallocated/distributed elements in a brokendown garments. A good layout is that

physical arrangement, which permits theproduct to be produced with minimum unitcost in the shortest time.

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Layout Procedure

1st Step:

Responsible person for layout making

APM

Team Leader TechnicianWork-Study Member

2nd Step:

To select line

To select style

To confirm total operator

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Layout Procedure

3rd step

To select breakdown the garments, elements byelements.

To put estimated SMV beside each elements/operation.

To calculate total SMV.

To select machine type & number.

To calculate average estimated SMV/Operator.

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Layout Procedure

Right operator for right operation/elementsaccording to performance.

To distribute/allocate elements (sequence) toeach operator by considering machine types,elements & estimated average (nearest) SMV.

To set up machine as per requirements.

It is mentionable that workflow should be forwarddirection.

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Benefit of Layout

The process distribution / work content willbe quite equivalent.

Usually an unexpected type of bottle neck

will not be found in line.No operator will be idle.

Can achieve the Buyers desire quality

level easily.Can reach the optimum target with in a

very short period.

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Line Balancing is to share work, to support

in another operation, to shift manpower

according to their capacity for equal

production in every point.

Line Balancing

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Necessity of line balancing

To get easily out put, it is necessary.

To get best performance of the workers, it is necessary.

To ensure of proper use of time & manpower, it isnecessary.

To follow up the line easily, it is necessary. To give the pressure to workers for optimum out put, it is

necessary.

To know the lines potential capacity of the line, it isnecessary.

To find out the productivity gap%, it is necessary. To take the next step for higher productivity at need the

line balancing report it is necessary.

To get higher productivity so much necessary.

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Bottleneck in line

Worker selection wrong.

Wrong works flow / sequence of works.

Non balance allocation of elements.

Works negligence by workers.

Workers absenteeism.

Machine disturbances / out of order.

Lack of supply.

Non serial supplies forward from workers.

Color shading.

Quality problem.

If any body becomes sick.

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Way of reducing bottle neck

To make size set sample minimum 15 to 10days before input.

To arrange pre- production meeting in time.

To prepare layout sheet before input in the line.

To check fabrics and accessories before issuingin the line.

To submit the layout sheet to maintenancesection minimum 2-3 days before for better

preparation.To check pattern before supply in the line.

To reduce excess works from workers.

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Way of reducing bottle neck

To select right workers for right works.

To keep supply available in time.

To maintain serial number.Reject garments should not forward.

Supply should be forwarded after checking.

To alert when bundling (maintain serial number)

By improving method.By improving workers performance.

By reducing sewing burst

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Job Description of IE

Operation bulletin & garments layout. Attain P.P meeting with production staff.

Daily production forecast meeting.

Daily line balancing & layout balancing.

Daily line target setup.

Production monitoring.

Bottleneck process monitoring & improvement. Motion study & method study.

Non productive time (Lost Time) record.

Machine Ratio (MRR) Report Man.

Machine servicing report follow-up.

Production plane monitoring co-ordinate.

QC pass report monitoring. Daily target & monthly efficiency, intensive list.

Ensure optimum use of machine.

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Job Description of IE

QC pass report monitoring.

Daily target & monthly efficiency, intensive list.

Ensure optimum use of machine.

Train up production staff on line balancing and efficiency.

All style monitoring for maintaining shipment schedule.

Make skill inventory.

Special increment for special skill operator (monitoring).

Monitoring and optimize rented machine.

Daily production, efficiency and manpower report.

Daily quality statistical report presentation.

Monthly production and shipment closing report.

Implement of 5s suggestion. Implement of kaizen suggestion

Arrange and design guide feed and folder on time (pre-productionattachments)

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Characteristics of a Work-Study Engineer

a) Education:

Good secondary education with an atitude for matriculation,formal education in engineering disciplines preferred.

b)Practical Experience:

Should include a period of working within one or more of theprocess within industry.

C)Personal Qualities:Sincerity & honesty

The work study person must be sincere and honest; only ifthis is the case will he or she gain the confidence andrespect of those with whom he or she will work.

EnthusiasmHe or she must be really keen on the job, believe in theimportance of what he or she is doing and be able totransmit enthusiasm to the people round about.

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Characteristics of a Work-Study Engineer

Tact/DiplomacyTact in dealing with people comes from understanding them andnot to wishing to hurt their feelings by unkind or thoughtlesswords, even when these may be justified. Without tact no Work-Study person is going to get very far.

Good Appearance

The person must be neat & tidy & look efficient. This will inspireconfidence among the people with whom he or she has to work.

Self confidence

This can only come with good training and experience of applying

work-study successfully. The work study practitioner must be ableto stand up to top management, supervisors or workers indefense of his or her opinions and findings, and to do so in such away that will respect and not give offence.