Training Session IE

BySandeep PrasadM.F.Tech , NIFT, India

Project AssociateETIDI-NIFT Twinning Arrangement

04/18/2023

A Session

onIndustrial Engineering

Session 1Date: October 09, 2015

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Training Overview

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Training Overview

9 Sessions of approx. 2 hrs. each

Shop floor assignments

Class room activities

Sessions Topics1 to 2 Industrial Engineering – Definition & Significance1 to 2 Scope of Apparel Engineering1 to 2 The Benefits of Engineering

3 to 4 Applications of Industrial Engineering3 to 4 Concept of Product Engineering5 to 6 Method Study5 to 6 Time & Motion Analysis5 to 6 Performance Development ( Capacity Study & Follow Up)7 to 9 Industry Visit and Practical Assignments

10 Presentation and Final Discussion

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Background

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Background

Lead times

Order Quantities

FOB Value & Margins

Quality Requirements

CostsUPWARD PRESSURES

DOWNWARD PRESSURES

Service Requirements

Our Costs are increasing everyday while the FOB values are decreasing thus causing excessive pressure on our

margins.

“It is reduction of costs

and hence improvement in margins and

that we talk about

in this document”

What is Happening to the Business?

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A look at the Cost…

Element % of Total Cost

Fabric 60-70%

Trims & Accessories 5-10%

CMP 15-30%

Others 5%

Total Cost of Garment 100%

Analysis of the cost sheet shows that the highest cost element is fabric cost. Hence the first step

to cost reduction is to reduce the cost of the highest cost incurring element i.e. fabric.

Fabric Cost represents 40-50% of the FOB Value and 60-70% of the total cost of the garment.

Hence a 5% saving in fabric consumption represents the equivalent of…

…3 to 3.5 % saving in total cost and…

…2% to 3% contribution to profit before taxes.

Background

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Cutting Room Cost Analysis

94.53%

1.63%3.85%Fabric

Total Labor Cost

Overhead

Fabric forms the biggest component at ~94.5% of Cutting Room Cost

Next biggest category is Total Labor Cost which is a function of Efficiency

PercentageFabric 94.53%Total Labor Cost 3.85%Overhead 1.63%

Background

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Efforts

MaterialUtilization

CuttingEfficiency

This Brings Us to Our Strategy…..

Background


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Understanding Work Content

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Stopwatch

It is the tool we use to determine how long it takes to do an

operation…

Conversions

SPLIT TIME: Split time is the time elapsed from the starting point

to a specific point

Going from Hour : Minutes to Hour : Hundredths

Going from Hour: Hundredths to Hour: Minutes

Use of Stopwatch

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Stopwatch

• SPLIT TIME: Split time is the time elapsed from the starting point to a specific

point

• LAP TIME: is the time elapsed for one time through the cycle or since the last

time the LAP button was pressed.

• TOTAL ELAPSED TIME: This is the total time the stopwatch has been

running since the START button was pressed

Use of Stopwatch

1st Split

2nd Split

3rd Split

1st Lap

2nd Lap

3rd Lap

TOTAL ELAPSED TIME

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Understanding SAM (Standard Allowed Minutes)

SAM is the inherent work content of any operation. It is the scientific measure of the work in any operation. It includes allowances for normal process associated with operation

The work content depends upon the method adopted – Similar to a situation when time required to reach a destination depends upon the way one select

Sum of all operations in a garment is the SAM of the garment

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Rating

Allowances

Basic Time

Standard Operator• Skilled• Experienced• Rhythmic• Handling• Quality• Etc.

• Pace• Skill• Rhythm• Etc.

• Normally Associated• Personal & Fatigue• Machine Delay

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How are SAMs arrived at ?

1.PDMTS (Pre-determined motion and time standards)

2.Past data

3.Time Study


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Calculating Output Targets, Machines and Man Power

Setting Piece Rates, Quotas

Doing Capacity Study

Preparing Operation Bulletin

Setting up Training Program

“Virtually every thing in Apparel Industry is based on SAMs”

Uses of SAM…

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Study the garment and list the number of fabric involved

Doing Time Study to Establish SAM…

Create Operation Sequence for each type of fabric till bundling

List their nature : Repetitive (Cyclic) or Non-repetitive

List variables and note how they are related to the quantity being produced

Conduct studies for both

List each if it’s a group activity or team activity

In case of team activity note the composition

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Observe the job and break it into Elements

Rate each Element by comparing with the acceptable standard

Use stop watch to time each Element

Average the observed element times

Multiply each element with the Rating to get Element’s Basic time

Add basic time for all the elements for operation to get Operation’s Basic Time

Add personal, Fatigue and Machine Delay allowance to get Standard Allowed Time for the variable

Doing Time Study to Establish SAM…

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Identify break points which are Distinguishable

Eliminate abnormal readings or extreme readings

Add proper Allowance

Be Cordial and Polite, but do not talk unnecessarily with operator

Never sit down or stand in front of operator

Understand the Correct Motion Pattern first before making time study

Important points while Doing Time Studies …

Derive per piece value

Derive per operator value

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Mathematically SAM is defined by following equation:

SAM per variable = ASCT X Rating % X (1+ PF% + MD%)

per team

SAM per piece = ASCT X Rating % X (1+ PF% + MD%)

per operator

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Manufacturing Standards provide the structure to improve productivity.

Standard MethodsThe elements (motions, machinery, environment) used to complete an

operation

Operations BulletinThe manufacturing steps required to

produce a style

Standard TimesTime required using standard

method plus allowances

Balance

Number of SAMs per Unit

SAM Data

Time required to produce Units

Resources required

Number of Units

Uses of SAM…

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Apparel Engineering…

Engineering - a science by which the properties of matter and the sources of energy in nature are made useful to man.

Industrial Engineering is the engineering approach applied to all factors, including the human factor, involved in the production and distribution of products and services.

Industrial Engineering Scope:

• Study, measure, and improve the way individuals perform their jobs

• Design and install a better system of coordinating the jobs assigned to individuals into a group effort

• Specify, predict, and evaluate results obtained

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Logically A logical way to find out:

•The best way to do something

• The time required to do it

•The way to measure results

Scope:

•Piece Rates

•Costing

•Manpower Planning

•Machine Requirements

•Production Planning

•Cut Order Planning

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•Plant Layout

•Production Flow System

•Cutting Section

Cutting Efficiency

Material Utilization

•Quality Control

•Distribution System

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Work Study: Fundamental Parts

Work Study

Method Study

Simplify the task (or

eliminate it)

‘Engineer the

operation’

Reduce the inherent work content taking account of the skill required to perform

the task set

Work Measurement

Measure the work content in the task

How long should it take a trained and motivated ‘standard’ operator to

perform the task

First

Then

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The Method Study ‘7 step’ procedure

1. Select........... Objectives

2. Define………. Relevant Data and Info.

3. Record ……….Relevant Data and Info.

4. Examine………Improved Methods

5. Develop ………Improved Methods

6. Install ……… Improved Methods

7. Maintain ………Improved Methods

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Operator’s Time

Shift Time: Total Time Factory works

Clock Time: Total time minus break time / Time for which operator is being paid

Off-standard Time: Time out of clock time for which operator is being paid, but he spends it being idle or doing some thing for which he is not responsible but being paid for

On-standard Time: Time out of clock time for which operator is being paid, but he spends it doing some thing for which he is responsible and being paid for

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Performance Metrics…

Output

Productivity

Efficiency

Performance

Utilization

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Output

• Talks about Quantity

• Does not consider variables or factors

• Can compare same product with exactly same factors/variables of production

• Limited use because of above limitation

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Productivity

• Talks about Quantity and Variables but within same products

• Cant compare different products

• Can compare same product with different variables of production

• Limited use because of above limitation

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Efficiency

• Ratio of SAM Produced (SAM X Output) and Man minutes (DL X Clock Time)

• Best tool for measurement as takes into account all the factor of production including changing product Profile

• Efficiency% = (SAM X Output X100) / (DL X Clock time)

• Good factories works at 70%

• Measures both operators skill and Management’s effectiveness

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Performance

• Ratio of SAM Produced (SAM X Output) and On-standard minutes (DL X On-standard Time)

• Best tool for measurement as takes into account all the factor of production including changing product Profile

• Performance% = (SAM X OutputX100) / (DL X On-standard minutes)

• Good factories works at 90-95%

• Measures operators skill

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Utilization

• Ratio of On-standard minutes and Clock time in minutes

• Very important factor telling how are available capacity being utilized

• Utilization% = On-standard time X 100 / Clock time

• Good factories works at 85%-95%

• Measures Management’s effectiveness

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How look at the complete Performance Metrics

Efficiency = Performance X Utilization

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Operation Bulletin…

Enter the Time Study Data

Enter relevant info

Get Spreading Locations

Do other calculations

Activity….


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Capacity Studies

When we make a capacity study on an operator, we are measuring the performance he/she should attain if he/she continues to work at the same pace and use the same method as observed during the study.

Need:• Capability of operator

• Motivate operator

• Training

Capacity %

Capacity gap %

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Capacity Studies

Basic Minutes• Maximum Potential Performance Level of Standard Operator

• ASCT X Rating %

• Gives Rating

Capacity gap %• Own capacity vs. own performance

• How much short capacity is getting converted to longer runs: Sprint vs. Marathon

Capacity %• Comparison with standard operator’s capacity

• ASCT compared with BM

• Gives Rating

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Capacity Studies

Capacity %• BM X 100 / ASCT

Capacity gap%• Capacity% - Performance

• [Capacity (pieces per duration) – Actual (Pieces per Duration)] / Capacity (pieces

per duration)

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Activities …

How many tables is required to cut 40,000 Pieces of Polo shirts in two shifts?

What should be the DL for each?

What would be the efficiency?

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Activities …

What is the spreading, cutting, bundling and total Cutting Section’s efficiency?

• Product = Polo Shirt

• Spreading DL = 98

• Spreading Output = 120,000 Pcs.

• Cutting DL = 60

• Cutting Output = 120,000 Pcs.

• Bundling DL = 200

• Bundling Output = 100,000

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Activities …

What is the spreading, cutting, bundling and total Cutting Section’s efficiency?

• Spreading Output of Polo Shirt = 30,000 Pcs.

• Spreading Output of Brief = 60,000 Pcs.

• Spreading DL = 98

• Cutting Output of Polo Shirt = 30,000 Pcs.

• Cutting Output of Brief = 60,000 Pcs.

• Cutting DL = 60

• Bundling Output of Polo Shirt = 20,000 Pcs

• Bundling Output of Brief = 55,000 Pcs

• Bundling DL = 200

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Activities …

How much time will Spreading take?

• Spreading Speed = 14 meters / minutes

• Lay Length = 9.25 meters

• Ply height = 120 plies

What is the efficiency at this?

How much time will Cutting take?

• Cutting Speed = 311 inches/ minutes

• Number of Bites = 9

• Perimeter = 1671 yards


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Activities …

How much time will Auto Spreading take?


• Lay Length = 9.25 meters



How much time will Auto Cutting take?


• Number of Bites = 9

• Dry haul = 0.16 minutes



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Activities …

SAM data base

Efficiency calculations

Spreaders’ Utilization

Table Utilization

Table Capacity / Total Cutting Room’s capacity for different products in Linear Length, Pieces and weight

Operations Bulletin

Spreading Speed

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Activities …

How much time will Auto Spreading take?


• Lay Length = 6 meters



How much time will Auto Cutting take?




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Activities …

SAM data base

Efficiency calculations

Spreaders’ Utilization

Table Utilization

Table Capacity / Total Cutting Room’s capacity for different products in Linear Length, Pieces and weight

Operations Bulletin

Spreading Speed

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Activities …

Maximum Marker Length Possibility and Actual with reasons

Maximum Ply height Possibility and Actual

Targets Vs. Actual – Spreading, cutting and bundling with reasons

CIDB reports reasons and actual / Cutters speed recording for different fabric

Respective Studies

Capacity Studies

Balanced Flow

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Activities …

MIS Flow Chart

Method Documentation

Documents

Training Session IE