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The document provides information on various topics related to industrial engineering in the apparel industry such as standard minute value, plan layout, throughput time, methods improvement, work study, time study, observed time, loss time, performance, work in progress, time measurement, method study, rating, target, bottlenecks, production line balancing, quality of work study executive, work place engineering, standard worker, general sewing data, capacity, effectiveness, equipment used for time study, 5S methodology, responsibilities of industrial engineers, types of waste, human body movements, work content, PDCA, marker, marker efficiency, fabric wastage, spreading, grain line, button ligne conversion, marking, marker width, GSM calculation, team development model

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Information of Industrial Engineering Department  SMV Standard minute value is the standard time, to complete any given task by using best possible methods at standard level of performance.  Plan Layout Plan is the special arrangement & configuration of departments. Work stations & equipment used in the conversion process.  TPT (Throughput time) Throughput time is the time taken by particular volume of work to complete.  Method improved  Select  Record  Examine  Develop  Evaluate  Define  Install  Maintain  Work study Work study is the systematic examination of the method of caring on activities  Time study To determine the time is should take for a qualified worker to perform a specific task using a specified method by directly observing on operator.  Step of the time study  -break the work into element  -How element are selected  Observed Time Time recorded by observing on operator while he she is doing a task.  Loss time Loss time is the ineffective or useless time that spends on any activity which is not a specified part of a job.  Performance This is a figure which we calculate after reducing the lost time out of the total available time.  WIP WIP is the number of garments under production at a given time.  Time measurement: Time measurement is the application of techniques designed to establish the time for a qualified worker to carry out a task at a defined level of performance.  Method study Method study is the systematic recoding & critical examination of ways of doing thing in order to make improvements.  Important consideration of the method study  Minimum motion of the human body  Arrangement of work place  Working condition  Process of manufacturing  Rating : Rating is the assessment of the workers rate of working relative to the observer’s concept of the rate corresponding to standard rate.  Rating errors:  Loose rating  Tight rating  Flat rating  Steep rating  Inconsistent rating.  Target Target is the amount of production which should be produced by an operator or a line that a management desires.  Bottleneck Which are holding up production operations or a lengthy operation that consumes a great deal of time.  Plan layout : Plan layout is the special arrangement & configuration of departments, work stations, & equipment used in the conversion process.  7M:  Manpower  Material  Money  Methods  Machine  Moral  Management of time  Need of apparel engineer:  Standardization of methods, equipment & conditions.  Production scheduling to work accurately help to understand how long it takes to complete the work.  Fair payment to employee. • Historical data: This is the technique of work measurement in this way we carry out an experiment & determine that time required for a certain operation. • Different types of allowances:  Relaxation allowance  M/C delay allowance  Contingency allowance • Operation breakdown: In the clothing industry operation breakdown is the separation of the making operations so that garments can be made up quickly & cheaply using available labor & machinery. • Production line balancing: Production line balancing is the allocation of the work to be done to the people available to do it production line balancing is used.  To ensure a steady flow of work  To make the best use of the available time &  To keep work in progress of a minimum. • Quality of Work study Executive:  Sincerity & Honesty  Enthusiasm  Tactful  Good appearance  Self confidence  Sympathy with people • Work place engineering:  Minimum working area: It indicates that place from where the operator can take his/her raw materials or cut panel without any movement of their task.  Maximum working area: It indicates that place from where the operator cannot take his/her raw materials or cut panel without any movement of their task. • Standard worker: The standard worker is that worker who has the consistency a qualified worker is one who has acquired the skill, knowledge & other attributes to carry out the work in hand to satisfactory standard of quality quantity & safety. • GSD: General sewing data is a technique for method analysis & setting of time standards for sewing products of industry. • Capacity: To check how many an operator can produce in one hour. • Effectiveness Means: Doing the right thing. • Effectiveness Means: Doing the thing right. • The Equipment used for time study:  Stop watch  Clip board  Time study format  Pencil  Eraser  Calculator • 5 s :  SEIRE (SORT)  SEITON (SET IN ORDER)  SEISO (SHINE)  SEIKETSU (STANDARDIZE) &  SHITSUKT (SUSTAIN). • Who are responsible for the implementation of 5S  Management commitment  Management envelopment  Participation by all  Supported by all  Self sustaining
• Responsibilities of IE Executive:  Establish a correct method  Establish a correct standards  Achieve operator’s performance. • 7 Wastage:  Delay / Waiting  Transportation  Excess motion  Over production  Inventory  Over processing  Defective parts / Alter • Movement’s motions of human body’s:  Finger  Wrist  Forearm  Upper arm  Shoulder • Work content:  Effective content o Basic work content  Ineffective work o Poor design o Incorrect quality o Poor layout o Poor planning o Absenteeism o Inefficiency o Occupational hazards • PDCA:  Plan  Do  Check  Action • What is marker Drawing the pattern on the paper as per style. • Objective of marker  To arrange for cutting  To share fabric  To make minimum wastage  To help for your cutting. • Marker Efficiency Additional of total area of all patterns in a marker (square inch) * 100 / total area of marker (square inch) • If the efficiency is high then wastage will be less. • Marker Efficiency Marker Efficiency = (Total area of marker / Total area of lay) * 100 • What factor are increasing marker efficiency  Size of garments  Marker length  Pattern engineering  Type of fabric  Symmetrical  Asymmetrical  Process of marker making  Width of marker  Types of garments • Fabric wastage outside of marker  Ends of ply losses (2+2=4)  Losses of fabric at the ends of roll  Selvedge losses : 2 % not more than 7 %  Purchase loss • Spreading To spread cloth as determined by needed quantity as per marking. • Grain line Parallel to grain line. • Button ligne Ligne = 1 inch / 40 “One inch ar 40 vager ak vag ke ligne bole”. 1 ligne = 0.625 mm If, 20 ligne = 20 * 0.625 mm = 12.5 mm So, the size of the button will be written as 20 L Converted: Ligne to mm 16 L so, 16 / 1.6 = 10 mm & Mm to ligne 10mm so, 10 * 1.6 = 16 L • What is marking It is the process by which all necessary patterns of all size are drawn on a marking paper by utilizing minimum area of the paper. • Marker width It is the width of marker, which is, determine by omitting the bode fabric from edge of the roll. Example: Width = 48” & 1” is bode fabric, so, marker width : 48 – 1 = 47” • GSM Calculation 1” = 2.54 cm 36” = 1 yards = 36 * 2.54 = 91.44 cm 2 yards = 91.44 * 2 = 182.88 cm / 100 = 1.8288 mm 4 yards = 91.44 * 4 = 365.76 cm / 100 = 3.6576 mm Area = 4 yards * 2 yards = 1.8288 * 3.6676 = 6.68901888 m2 Now, 2 kg = 2 * 1000 gm = 2000 gm So, 6.68901888 m2 = 2000 gm ; ‘GSM = 2000 / 6.68901888 = 298.997 ~ 299 • Team Development model  Forming  Storming  Norming  Performing  Adjourning • Seam types  Supper imposed seam  Lapped seam  Bound seam  Flat seam  Decorative seam  Edge neatening seam  Seam class – 7  Seam class – 8 • Poly bag is made of two type of chemicals  Poly propylene  Poly ethylene Poly ethylene is costly then poly propylene. • Classification of stitch  Chine stitch (Hem, Button)  Hand stitch (Jacket edge )  Lock stitch (pocket, Caller, Cuff T/S)  Multithread chain stitch ( F/L less, Bread, Elastic )  Over edge stitch (O/L)  Cover chain stitch ( F/L , Kansie ) • Care label code Normal Wash Chlorine blasé Iron code Dry Clean code Drying condition • The sub holding of Workstudy department  Planning  Discipline  Motivation  Follow up  Productivity  Quality  Training • GSD GSD = (Man power * Work hour) / Target • SMV SMV = Basic time + (Basic time * Allowance) • Basic time Basic time = Observed time * Rating 4 yards Wait = 2 kg 2 yards
• Observed time Observed time = Total Cycle time / No of cycle • Rating Rating = (Observed Rating * Standard rating) / Standard rating • Efficiency Efficiency = (Earn minute * Available minute) * 100 • Earn minute Earn minute = No of Pc’s (Production) * Garments SMV • Available minute Available minute = Work hour * Manpower • Organization Efficiency Organization Efficiency = (Basic pis time / Bottle neck time) * 100 • Basic pis time (BPT) Basic pis time = Total Gmt SMV / Total Manpower • UCL UCL = Basic pis time / Organization Efficiency • LCL LCL = 2 * Basic pis time – UCL • Improvement Improvement = 1 – (Production / Capacity) • Performance Performance = {Earn minute * (Available minute – Off standard time)} * 100 • Balancing loss Balancing loss = {AML – (TML/AML)} * 100 • TML TML = Operational SMV / BPT • Balancing Efficiency Balancing Efficiency = 1 - Balancing loss • Capacity Capacity = 60 / Capacity time in minute • Cycle Time Cycle Time = 60 / Team target • Team target Team target = (Work hour/SMV) * Present operator * Organizational efficiency • Capacity Achievable Capacity Achievable = Capacity * Balance • Balance Balance = BPT / Bottle neck time (BNT) • Standard time Standard time = Net operation time * (1 + Ratio of loss time) • Daily output Daily output = Work hour / SMV • Factory capacity Factory capacity = (Work hour / SMV) * Total worker * Working day * Efficiency • CPM CPM = (Total over head cost of the month / No of SMV earners * Work minutes) *Efficiency • Required no of operator Required no of operator = Target daily output / Daily output per operator • CM of garments CM of garments = Total production / (No of worker * Work hour) • Marker Efficiency Marker Efficiency = (Total area of marker / Total area of lay) * 100 • CPD (Consumption per dozen) CPD = Marker length * Marker width * GSM * 12 / (1000 * 100 * 100 * Total marker pc’s) • Stitch Consumption Single Needle:  S/N 1 inch = 2.75 inch  D/N 1 inch = 6 inch Over Lock:  O/L 3TH 1 inch = 14 inch  O/L 4TH 1 inch = 17.75 inch  O/L 5TH 1 inch = 20 inch Flat Lock:  F/L 2TH 1 inch = 10.25 inch  F/L 3TH 1 inch = 14 inch  F/L 4TH 1 inch = 17.75 inch  F/L 5TH 1 inch = 22.75 inch FOA:  1TH 1 inch = 14 inch Button Stitch:  1 Button = 4~6 inch Button Attach:  1 Hole = 5 inch Bar tack:  1 Bar tack = 9 inch Lopper:  1 inch = 9 inch Latus:  1 inch = 30 inch

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  • 1. Information of Industrial Engineering Department  SMV Standard minute value is the standard time, to complete any given task by using best possible methods at standard level of performance.  Plan Layout Plan is the special arrangement & configuration of departments. Work stations & equipment used in the conversion process.  TPT (Throughput time) Throughput time is the time taken by particular volume of work to complete.  Method improved  Select  Record  Examine  Develop  Evaluate  Define  Install  Maintain  Work study Work study is the systematic examination of the method of caring on activities  Time study To determine the time is should take for a qualified worker to perform a specific task using a specified method by directly observing on operator.  Step of the time study  -break the work into element  -How element are selected  Observed Time Time recorded by observing on operator while he she is doing a task.  Loss time Loss time is the ineffective or useless time that spends on any activity which is not a specified part of a job.  Performance This is a figure which we calculate after reducing the lost time out of the total available time.  WIP WIP is the number of garments under production at a given time.  Time measurement: Time measurement is the application of techniques designed to establish the time for a qualified worker to carry out a task at a defined level of performance.  Method study Method study is the systematic recoding & critical examination of ways of doing thing in order to make improvements.  Important consideration of the method study  Minimum motion of the human body  Arrangement of work place  Working condition  Process of manufacturing  Rating : Rating is the assessment of the workers rate of working relative to the observer’s concept of the rate corresponding to standard rate.  Rating errors:  Loose rating  Tight rating  Flat rating  Steep rating  Inconsistent rating.  Target Target is the amount of production which should be produced by an operator or a line that a management desires.  Bottleneck Which are holding up production operations or a lengthy operation that consumes a great deal of time.  Plan layout : Plan layout is the special arrangement & configuration of departments, work stations, & equipment used in the conversion process.  7M:  Manpower  Material  Money  Methods  Machine  Moral  Management of time  Need of apparel engineer:  Standardization of methods, equipment & conditions.  Production scheduling to work accurately help to understand how long it takes to complete the work.  Fair payment to employee. • Historical data: This is the technique of work measurement in this way we carry out an experiment & determine that time required for a certain operation. • Different types of allowances:  Relaxation allowance  M/C delay allowance  Contingency allowance • Operation breakdown: In the clothing industry operation breakdown is the separation of the making operations so that garments can be made up quickly & cheaply using available labor & machinery. • Production line balancing: Production line balancing is the allocation of the work to be done to the people available to do it production line balancing is used.  To ensure a steady flow of work  To make the best use of the available time &  To keep work in progress of a minimum. • Quality of Work study Executive:  Sincerity & Honesty  Enthusiasm  Tactful  Good appearance  Self confidence  Sympathy with people • Work place engineering:  Minimum working area: It indicates that place from where the operator can take his/her raw materials or cut panel without any movement of their task.  Maximum working area: It indicates that place from where the operator cannot take his/her raw materials or cut panel without any movement of their task. • Standard worker: The standard worker is that worker who has the consistency a qualified worker is one who has acquired the skill, knowledge & other attributes to carry out the work in hand to satisfactory standard of quality quantity & safety. • GSD: General sewing data is a technique for method analysis & setting of time standards for sewing products of industry. • Capacity: To check how many an operator can produce in one hour. • Effectiveness Means: Doing the right thing. • Effectiveness Means: Doing the thing right. • The Equipment used for time study:  Stop watch  Clip board  Time study format  Pencil  Eraser  Calculator • 5 s :  SEIRE (SORT)  SEITON (SET IN ORDER)  SEISO (SHINE)  SEIKETSU (STANDARDIZE) &  SHITSUKT (SUSTAIN). • Who are responsible for the implementation of 5S  Management commitment  Management envelopment  Participation by all  Supported by all  Self sustaining
  • 2. • Responsibilities of IE Executive:  Establish a correct method  Establish a correct standards  Achieve operator’s performance. • 7 Wastage:  Delay / Waiting  Transportation  Excess motion  Over production  Inventory  Over processing  Defective parts / Alter • Movement’s motions of human body’s:  Finger  Wrist  Forearm  Upper arm  Shoulder • Work content:  Effective content o Basic work content  Ineffective work o Poor design o Incorrect quality o Poor layout o Poor planning o Absenteeism o Inefficiency o Occupational hazards • PDCA:  Plan  Do  Check  Action • What is marker Drawing the pattern on the paper as per style. • Objective of marker  To arrange for cutting  To share fabric  To make minimum wastage  To help for your cutting. • Marker Efficiency Additional of total area of all patterns in a marker (square inch) * 100 / total area of marker (square inch) • If the efficiency is high then wastage will be less. • Marker Efficiency Marker Efficiency = (Total area of marker / Total area of lay) * 100 • What factor are increasing marker efficiency  Size of garments  Marker length  Pattern engineering  Type of fabric  Symmetrical  Asymmetrical  Process of marker making  Width of marker  Types of garments • Fabric wastage outside of marker  Ends of ply losses (2+2=4)  Losses of fabric at the ends of roll  Selvedge losses : 2 % not more than 7 %  Purchase loss • Spreading To spread cloth as determined by needed quantity as per marking. • Grain line Parallel to grain line. • Button ligne Ligne = 1 inch / 40 “One inch ar 40 vager ak vag ke ligne bole”. 1 ligne = 0.625 mm If, 20 ligne = 20 * 0.625 mm = 12.5 mm So, the size of the button will be written as 20 L Converted: Ligne to mm 16 L so, 16 / 1.6 = 10 mm & Mm to ligne 10mm so, 10 * 1.6 = 16 L • What is marking It is the process by which all necessary patterns of all size are drawn on a marking paper by utilizing minimum area of the paper. • Marker width It is the width of marker, which is, determine by omitting the bode fabric from edge of the roll. Example: Width = 48” & 1” is bode fabric, so, marker width : 48 – 1 = 47” • GSM Calculation 1” = 2.54 cm 36” = 1 yards = 36 * 2.54 = 91.44 cm 2 yards = 91.44 * 2 = 182.88 cm / 100 = 1.8288 mm 4 yards = 91.44 * 4 = 365.76 cm / 100 = 3.6576 mm Area = 4 yards * 2 yards = 1.8288 * 3.6676 = 6.68901888 m2 Now, 2 kg = 2 * 1000 gm = 2000 gm So, 6.68901888 m2 = 2000 gm ; ‘GSM = 2000 / 6.68901888 = 298.997 ~ 299 • Team Development model  Forming  Storming  Norming  Performing  Adjourning • Seam types  Supper imposed seam  Lapped seam  Bound seam  Flat seam  Decorative seam  Edge neatening seam  Seam class – 7  Seam class – 8 • Poly bag is made of two type of chemicals  Poly propylene  Poly ethylene Poly ethylene is costly then poly propylene. • Classification of stitch  Chine stitch (Hem, Button)  Hand stitch (Jacket edge )  Lock stitch (pocket, Caller, Cuff T/S)  Multithread chain stitch ( F/L less, Bread, Elastic )  Over edge stitch (O/L)  Cover chain stitch ( F/L , Kansie ) • Care label code Normal Wash Chlorine blasé Iron code Dry Clean code Drying condition • The sub holding of Workstudy department  Planning  Discipline  Motivation  Follow up  Productivity  Quality  Training • GSD GSD = (Man power * Work hour) / Target • SMV SMV = Basic time + (Basic time * Allowance) • Basic time Basic time = Observed time * Rating 4 yards Wait = 2 kg 2 yards
  • 3. • Observed time Observed time = Total Cycle time / No of cycle • Rating Rating = (Observed Rating * Standard rating) / Standard rating • Efficiency Efficiency = (Earn minute * Available minute) * 100 • Earn minute Earn minute = No of Pc’s (Production) * Garments SMV • Available minute Available minute = Work hour * Manpower • Organization Efficiency Organization Efficiency = (Basic pis time / Bottle neck time) * 100 • Basic pis time (BPT) Basic pis time = Total Gmt SMV / Total Manpower • UCL UCL = Basic pis time / Organization Efficiency • LCL LCL = 2 * Basic pis time – UCL • Improvement Improvement = 1 – (Production / Capacity) • Performance Performance = {Earn minute * (Available minute – Off standard time)} * 100 • Balancing loss Balancing loss = {AML – (TML/AML)} * 100 • TML TML = Operational SMV / BPT • Balancing Efficiency Balancing Efficiency = 1 - Balancing loss • Capacity Capacity = 60 / Capacity time in minute • Cycle Time Cycle Time = 60 / Team target • Team target Team target = (Work hour/SMV) * Present operator * Organizational efficiency • Capacity Achievable Capacity Achievable = Capacity * Balance • Balance Balance = BPT / Bottle neck time (BNT) • Standard time Standard time = Net operation time * (1 + Ratio of loss time) • Daily output Daily output = Work hour / SMV • Factory capacity Factory capacity = (Work hour / SMV) * Total worker * Working day * Efficiency • CPM CPM = (Total over head cost of the month / No of SMV earners * Work minutes) *Efficiency • Required no of operator Required no of operator = Target daily output / Daily output per operator • CM of garments CM of garments = Total production / (No of worker * Work hour) • Marker Efficiency Marker Efficiency = (Total area of marker / Total area of lay) * 100 • CPD (Consumption per dozen) CPD = Marker length * Marker width * GSM * 12 / (1000 * 100 * 100 * Total marker pc’s) • Stitch Consumption Single Needle:  S/N 1 inch = 2.75 inch  D/N 1 inch = 6 inch Over Lock:  O/L 3TH 1 inch = 14 inch  O/L 4TH 1 inch = 17.75 inch  O/L 5TH 1 inch = 20 inch Flat Lock:  F/L 2TH 1 inch = 10.25 inch  F/L 3TH 1 inch = 14 inch  F/L 4TH 1 inch = 17.75 inch  F/L 5TH 1 inch = 22.75 inch FOA:  1TH 1 inch = 14 inch Button Stitch:  1 Button = 4~6 inch Button Attach:  1 Hole = 5 inch Bar tack:  1 Bar tack = 9 inch Lopper:  1 inch = 9 inch Latus:  1 inch = 30 inch