Industrial Engineering

# What is Industrial Engineering ?

Industrial Engineering is the technique for developing productivity by proper using of manpower, machine, current infrastructures & facilities of the factory.

Definition of Work Study

Work-Study is the critical examination of human works for increasing productivity. It is the systematic examination of the methods of carrying out activities 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 and work measurement, which are used in the examination of human work in all its contexts, and which lead systematically to the investigation of all the factors which affect the efficiency and economy of the situation being reviewed, in order to effect improvement. This has to do with Productivity Improvement, but also improvement quality .

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 per standard methods.

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

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.

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.

Motion Study
Motion Study is to standardize working motion of the manpower. 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

Time Study
Time study is very important analysis for finding SMV. Condition of time study: Before making the time study, the work study officer ensure that conditions on the job 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.

Techniques of Time study

Assess the performance of the worker. Understand the flow of work. Time study person should not disturb the operators . 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.

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 skill and effort. Apply the standard job allowances to allow for the times when the operator would not be at the machine sewing. Set the time production quota expected of the 100% (Average ) operator.

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 = 90 Mr. Johns Rating = obs. Rating / stnd. Rating =90/100 =0.90 2. Mr. Mill can adjust within 8 seconds. Mr. Mills observed Rating = 45 Mr. Mills Rating = obs. Rating / stnd. Rating =45/100 =0.45 So, Mr. Johns Rating higher than Mr. Mill.

Breakdown/Dividing/Operation Bulletin
Breakdown is a listing of the content of a job by elements. A garment consists of some parts & some group of operations. Breakdown means to writing down all parts & all process/operation after one another lying with the complete garment according to process sequence. It is a must to write down the estimated SMV & type of machine beside each & every process.

Breakdown procedure
APM, Technician Chief & Work-Study officer must sit together to make breakdown. Technician breaks the garments into parts and gathered 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 SMV and the total will be called as respective garments SMV .

Layout
Layout means to distribute/allocate elements to the individual operator in the line by considering total worker, worker experience, total machine, types of machine & mainly the estimated SMV of allocated/distributed elements in a broken down garments. A good layout is that physical arrangement, which permits the product to be produced with minimum unit cost in the shortest time.

Layout Procedure
1st Step: Responsible person for layout making APM Team Leader Technician Work-Study Member 2nd Step: To select line To select style To confirm total operator

Layout Procedure
3rd step

To select breakdown the garments, elements by elements.

To put estimated SMV beside each elements/operation. To calculate total SMV. To select machine type & number. To calculate average estimated SMV/Operator.

Layout Procedure
Right operator for right operation/elements according to performance.

To distribute/allocate elements (sequence) to each operator by considering machine types, elements & estimated average (nearest) SMV. To set up machine as per requirements.
It is mentionable that workflow should be forward direction.

Benefit of Layout
The process distribution / work content will be 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.

Line Balancing
Line Balancing is to share work, to support in another operation, to shift manpower according to their capacity for equal production in every point.

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 is necessary. 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 is necessary. 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.

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.

Way of reducing bottle neck

To make size set sample minimum 15 to 10 days before input. To arrange pre- production meeting in time. To prepare layout sheet before input in the line. To check fabrics and accessories before issuing in the line. To submit the layout sheet to maintenance section minimum 2-3 days before for better preparation. To check pattern before supply in the line. To reduce excess works from workers.

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

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.

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-production attachments)

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 the process within industry. C)Personal Qualities: Sincerity & honesty The work study person must be sincere and honest; only if this is the case will he or she gain the confidence and respect of those with whom he or she will work. Enthusiasm He or she must be really keen on the job, believe in the importance of what he or she is doing and be able to transmit enthusiasm to the people round about.

Characteristics of a Work-Study Engineer

Tact/Diplomacy Tact in dealing with people comes from understanding them and not to wishing to hurt their feelings by unkind or thoughtless words, even when these may be justified. Without tact no WorkStudy person is going to get very far. Good Appearance The person must be neat & tidy & look efficient. This will inspire confidence 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 able to stand up to top management, supervisors or workers in defense of his or her opinions and findings, and to do so in such a way that will respect and not give offence.