Nowadays Industrial engineering is treated one of the important element in the garment industry to improve productivity and secure requested delivery date. If production lines don’t chase the targeted plan that will bring worst situation for the owners and company will lose goodwill from their customers forever. Industrial engineering which is indicated in IE is a complete science to do research and analysis to get the best output from existing resource and manpower. IE department will find obstacles from production floor and will provide positive result oriented suggestions for optimum outcome. Thus, the importance of Industrial engineering is increasing rapidly for the garment owners.
Today I will try to share my gathered experience regarding the importance of Industrial engineering and their deals with the following activities:
1) Prepare existing manpower and machine report for the best use of resources
2) Accurate SMV calculation by time study
3) List up operator’s skill summery to do layout smoothly
4) Train up production staffs regularly to improve efficiency.
5) Improving productivity through a complete analysis of the process by process
6) Helping to launch TQM (Total quality management) system in a factory
7) Implement traffic light system on the floor and reduce sewing defect percentage
8) Check fabric, accessories and thread consumption before insert into production line to erase hassle
9) Before insert into production line, IE people should analysis developed samples to identify obstacles and make easier sewing process
10) Provide actual material requirement before insert into production line so that supply chain management can procure shortage materials quickly
11) Emphasize on process-wise operator skill development
12) Time study, motion study for the betterment of production process
13) 5S implementation, training, and auditing to reduce wastage
14) Work on 7 QC tools to minimize defects
15) Nonproductive time (Loss time) count properly and minimize
16) Hourly production monitoring and achieve the line target
17) Taking the capacity study of full-line and line balancing for clean up bottleneck area
18) Methods development and analysis to increase product quality and quantity
19) Should have a sound idea on quality methods to keep product quality
20) Manpower budget planning
21) Capacity study
22) PDCA cycle
23) Statistical analysis for continuous quality improvement
24) Production planning and control to chase production targets
25) Line cost calculation, floor capacity calculation
26) Follow up KPI (key performance indicator) and report to seniors
27) 7 wastage reduce
28) Production study
29) CPM, CM calculation
30) Inventory control in all section
31) SPM, EPM, PCL calculation
32) Reduce WIP (work in progress)
33) Operator, line and floor efficiency calculation
34) Manpower requisition and set up
35) Eliminating excess manpower
36) Prepare operation break down, operation bulletin or layout to get output quickly
37) Follow up the low performing operators and deliver proper guideline to improve efficiency
38) Implementation of lean manufacturing tools and six-sigma
39) Select skill workers and provide incentives to operators and production staffs to get inspired
40) Co-ordination with merchandisers, review upcoming samples to make easy sewing process
41) Continuous research, analysis, and development to reduce costs. Do innovation to increase productivity
42) Work simultaneously with the quality department as well as merchant team to increase productivity and product quality
43) Co-ordination with maintenance team once review upcoming samples and suggest to procure new machines if required
44) Have to submit report to management regarding production target, achievement, improvement, training, and future plan through excel, graphics and power point presentation
45) Attend HR & compliance meeting. Discuss production obstacles and find a way of motivational elements to enhance workers interest. Later deliver their speech to production people.
Conclusion: IE people have to stay on the production floor all the time. Thus, they can motivate production workers easily by interacting and commanding voice. In a nutshell we can say industrial engineering is a bundle of techniques and innovations for the betterment of any company. I have tried to narrate their importance and activities in a short to get a sound idea at a glance of Industrial engineering in the garment industry.
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