1. BASIC INDUSTRIAL ENGINEERING TERMS
PRESENTED BY,
SHARMIN AKTHER DIBA
EXECUTIVE,CENTRAL IE
METRO KNITTING & DYEING MILLS LTD.
BEACON KNITWEAR LTD.

2. WHAT IS INDUSTRIAL ENGINEERING ?
DEALS WITH OPTIMIZATION OF COMPLEX PROCESSES,SYSTEMS OR METHODS
OPTIMIZATION OF 5M (MAN,M/C,MATERIAL,METHOD & MONEY) INSTEAD OF REDUCTION.
INDUSTRAIL EMGINEERING IS A COMBINATION OF ANALYSIS,MEASURE,PLAN,ACT & RESULT
IT’S AN ORGANIZATIONAL APPROACH TO GET MAX RESULT USING MIN EFFORT
IE = PROD ⤒ COST ⤓ MP ⤓ EFFICIENCY ⤒ QUALITY ⤒ PROFIT ⤒
EVERENDING DYNAMIC APPROACH TO IMPROVE
ITS WHERE ENGINEERING MEETS WITH BUSINESS

3. STANDARD MINUTE VALUE(SMV)
SMV defined as " Time taken by a standard worker to perform the task with pre- defined conditions"
SMV = BASIC TIME + (BASIC TIME × ALLOWANCE)
Suppose to complete an operation, an standard operator takes 1 minute.
We put 15% allowance(Men, M/c & Time)
SMV=1+(1×.15) Min
=(1+.15) Min
=1.15 Min
GMT SMV is the sum of SMV for all M/c & Manual operation to complete an item

4. RELATED TERMS TO SMV(Cont..)
Standard Operator : For a specific item & style, the potential operator who can give maximum output with best quality & can improve productivity.
Lets see an Example for better understanding,
Batsman faces 10 balls to score 5 Runs
Batsman faces 10 balls to score 12 runs
Batsman faces 10 balls to score 10 runs.
Obviously 2nd one is the potential batsman who uses his
inputs(balls) to get maximum output(Runs)
Minimum Input
Suppose 100 Pcs Cutting Input
Operation
Operator takes 1 hr transform 100 inputs to 95 outputs
Maximum output
Standard operator

5. RELATED TERMS TO SMV
Pre-defined Conditions : On time input arrival, single piece flow, running m/c conditions, defined quality status etc. are called pre-defined conditions.
Basic Time : Actual time to complete an operation. In other word, basic time is the pick & drop time including operation for quality output.
Basic Time= Pick time + Operation + Drop time;
Result , Input=Output with required quality
In a broad sense , a GMT SMV=Sum of all operation SMV, not SMV of GMT + allowance.

6. EFFICIENCY
EFFICIENCY defined as ‘’The comparison of what is actually produced or performed with what can be achieved with the same consumption of resources (Men, M/c, Material etc. )’’
EFFICIENCY = EARNED MINUTE/AVAILABLE MINUTE
EARNED MINUTE = PRODUCTION(PCs) × SMV
AVAILABLE MINUTE = MANPOWER(HEL+OPR) × WORKING TIME(MIN)

7. EFFICIENCY % CALCULATION
Suppose any GMT item SMV is 5.5 (For any fixed style SMV always fixed)
We use 22 Manpower(Operator & Helper) to achieve 1500 Pcs for 10 hour working shift
EARNED MINUTE = 1500× 5.5 or 8250 Min
AVAILABLE MINUTE = 22× (10×60) or Min
EFFICIENCY = 8250 Min/13200 Min or 0.625
Efficiency is expressed as % ,Then EFFICIENCY =(0.625 ×100)% or 62.50%
Efficiency is a ratio , not a number.
Efficiency vary with LEAD TIME & QUANTITY . More Lead time & Quantity Increase Efficiency , on the other hand less lead time tends us to use more MP or time to get required output , so efficiency reduces.

8. LINE TARGET Target= (total MP X WH X 60)/SMV
Suppose We have 22 MP for 10 hr .GMT SMV is 5.5
TGT=(22 X10 X60)/5.5
=2400 PCs/Hr (That is 100% TGT)
For expected efficiency this 100% TGT is multiplied by efficiency to fix Line Target
LINE TGT=(2400X.625) ;[Lets , we have expected efficiency of 62.5%)
=1500 PCs or 150PCs/Hr

9. CPM & CM
Minute cost or Cost per Minute(CPM) calculation for the garments sewing line is too much needy to earn maximum profit from an export order.
CPM (Cost Per Minutes)= (Direct Labor Cost + Operational Cost)of the month/ Usage Minutes (Available Minutes) of the month.

10. CM/COM/MC
Cost of Making(CM/COM)/Manufacturing cost(MC) have to calculate after calculating factory CPM.
CM= (SMV × CPM)/ Expected Efficiency%
Suppose , any GMT item SMV is 5.5,Expected efficiency = 62.5 % , CPM[let] = $0.0264
CM = (5.5 × .0264)/ .625
= $0.23/PCs
= ($0.23 ×12)/Dzn
=$2.79 /Dzn

11. Broad Calculation of Garments CM
To find out the CM (Cost of Making) of a item you must need the following 06 (six) information at first, as listed below:
i. Monthly total expenditure of your factory with factory rent, commercial cost, electricity bill, water bill, transportation, repairing, worker & stuff wages etc. (8hrs/day) in Bangla taka.
Suppose -50,00,000/-tk
ii. Qty of running Machine of your factory of the following month (which total expenditure we have consider here). Suppose -100 machines.
iii. Number of machine to complete the layout for the following Items (which CM we are calculating). Suppose- 25 machines.
iv. Production target/capacity of the following items, per hour from the existing layout, excluding alter & reject. Suppose-200 pcs per hour.
v. Total working day of the followings month,(though the house rent, commercial expenses, machine overhauling & some other cost remain same) Suppose-26 days.
vi. If you want to calculate the CM in US$ (dollar) then pls input present dollar conversation Rate BDT Suppose- $1 = 80 taka.

12. COST OF MAKING (CM) RULE:
={(Monthly total expenditure of the following factory/ 26) / (Qty of running Machine of your factory of the following month) X (Number of machine to complete the layout)} / [{(Production capacity per hr from the existing layout, excluding alter & reject) X 8}] X 12 / (Dollar conversion rate)
= [{(50,00,000 / 26) / ( 100) X (25)} / {(200) X 8}] X 12 / 74
= [{ / (100) X (25) } / 1600] X 12 / 74
= (48,076.9 / 1600) X 12 / 74
= X 12 / 74
= / 74
= $4.873 / dozen (this is the making cost (12 pcs) of the following items)
However, normally at present (after starting the new salary scale) in Bangladesh we calculate the CM of any item consider the overhead sewing machine cost 1200 tk to 1400 tk/day that means $ to $18.92/per day. Above is for a non-compliance factory.
For the a compliance factory the per day machine cost will be 1800 tk to 2100 tk
( $24.32 to $28.37)
SO, if the an items produce 1600 pcs per day using 25machines then the CM will be
= Overhead machine cost X require machine / produce quantity X 12 / $74
= 1400 X 25 / 1600 X 12 / 74
= $3.547/DOZ

13. CONVENTIONAL VS MODERN PROFIT THEORY
COST + PROFIT = PRICE
Modern :
PRICE – COST = PROFIT
Price should be moderate to get maximum order !
Cost should be minimized to get maximum profit !

14. WORK STUDY
SYSTEMATIC STUDY OF METHODS OF WORK TO IMPROVE EFFECTIVENESS & SET STANDARDS
2 STAGES :
1. METHOD STUDY : STUDY OF CURRENT METHOD & FIND OUT TO IMPLEMENT IMPROVED METHOD
2. WORK MEASUREMENT : DETERMINE THE STANDARD TIME REQUIRED TO COMPLETE IMPROVED METHOD
BENEFITS OF WORK STUDY :
PRODUCTIVITY IMPROVEMENT
EFFICIENCY INCRESE
IMPROVED WORK FLOW
IMPROVED WORK LAYOUT
IMPROVED STANDARDS

15. TIME & MOTION STUDY
TIME STUDY : A WORK MEASURING TECHNIQUE TO CALCULATE BASIC TIME BY FINDING CYCLE TIME & ADDING ALLOWANCE
MOTION STUDY : A TECHNIQUE TO ANALYZE OPERATORS MOTION & SET STANDARD BY ELIMINATING UNNECESSARY MOTION
TWO DIFFERENT THEORY BUT NEED PARALLEL RUNNING TO IMPROVE SYSTEM KNOWN AS ‘METHOD ENGINEERING’
TIME & MOTION STUDY IS A CONJUGAL TECHNIQUE TO PROCESS CONTROL,IMPROVE DISSIMILAR WORK PERFORMANCE & SET STANDARD GOALS
‘’IE IS A COMBINE PACKAGE TO IMPROVE BY TIME STUDY,WORK STUDY & MOTION STUDY’’

16. LINE BALANCING
LINE BALANCING IS A MANUFACTURING ENGINEERING FUNCTION IN WHICH WHOLE COLLECTION OF PRODUCTION-LINE TASKS ARE DIVIDED INTO EQUAL PORTIONS.
WELL BALANCED LINES AVOID LABOR IDLENESS & IMPROVE PRODUCTIVITY
LINE BALANCING IS FOR KEEPING WORK LOAD(THEARETICAL MP/ACTUAL MP) AS 1 OR LESS THEN 1 BY BALANCING WORK AS PER CAPACITY & TARGET
LINE LAYOUT
CAPACITY STUDY
CAPACITY GRAPH
FIND BOTTLENECK
METHOD ENGINEERING
LINE BALANCING

17. STEPS FOR LINE BALANCING
‘BOTTLENECK’ (CONSTRAINT M/C OR MP OR OPERATION THAT REDUCES PRODUCTIVITY) HAVE TO FIND OUT
FIND SAME M/C / M/C CONDITION SUCH AS GAUGE/PRESSURE FEET/DEVICE/THREAD ETC
FIND OUT OPERATION TO BALANCE WITH BOTTLENECK BY CHECKING WITH HIGER CAPACITY
BALANCING OPERATOR TIME STUDY ,MOTION STUDY & PRODUCTION STUDY
FIND BALANCED OPERATION EVERY MOTION CT(CYCLE TIME)
ELIMINATING NON VALUE ADDED TIME & SAM & CAPACITY CALCULATION
OPERATION BALANCING/HR ACCORDING TO TARGET & BALANCED OPERATOR CAPACITY

18. EXAMPLE-LINE BALANCING FOR ITEAM T-SHIRT
SL NO.
OPERATIONS
M/C /HELPER MP
IMBALANCED CAPACITY/HR
BALANCED CAPACITY/HR
BALANCING OPERATION 1
Front n back n 1st shoulder join with / without tape
4TH/OL 2
162 NO
Neck binding
FLAT BED
160 3
2nd Shoulder inner tack
SNLS
164 4
2nd shoulder join with / without tape
180
BALANCE (6) 20 PCs/HR 5
Secure 2nd neck 6
Sleeve n body match n insert sleeve
140
BALANCE WITH (4) 7
Care Label Make
161 8
Side/ sleeve Seams inc. care label and Gmts turns 9
Sleeve hem
2TFL
130
BALANCE WITH (10) 10
Bottom Hem
190
BALANCE (9) 30 PCs/HR 11
Thread trims & sticker remove
MNL
165

20. CORE LESSON FROM LEARNING
SMV & IT’S USE IN GARMENTS/APPAREL INDUSTRY
EFFICIENCY CALCULATION & ITS RELEVANT TERMS
CPM & CM CALCULATION FOR GARMENTS INDUSTRY
WORK STUDY,TIME & MOTION STUDY
LINE BALANCING & HOW TO APPLY PRACTICALLY

21. THANK YOU