Garment Industrial Engineering (IE) objective, roles, tools

Industrial Engineering:

According to the Institute of Industrial and Systems Engineers (IISE)

“Industrial Engineering is concerned with the design, improvement, and installation of integrated systems of people, materials, information, equipment, and energy.”

Industrial Engineering is an engineering discipline that is focus on designing, improving, and making systems more efficient by effectively managing manpower, materials, information or data, equipment, energy, and other resources.

To put it simply, Industrial Engineering is not just about increasing productivity or measuring operator efficiency. It is about finding better ways to use manpower, machines, materials, time, and other resources so that the system can work more efficiently and effectively.

Objective of Industrial Engineering:

  1. Increase productivity by improving processes, methods, and resource utilization.

  2. Improve work processes by reducing unnecessary motions and simplifying operator movements.

  3. Minimize Work in Process (WIP) and identify and eliminate production bottlenecks.

  4. Improve operational efficiency by optimizing production methods and resource usage.

  5. Optimize the man-machine ratio to ensure effective utilization of both manpower and machine

  6. Reduce production costs, waste, and defects through continuous process improvement and better resource management.

  7. Achieve Key Performance Indicator (KPI) targets by regularly monitoring performance and taking corrective measures when required.

  8. analys operator and staff performance, identify training requirements, support career development, and address performance or disciplinary issues when necessary.

  9. Set daily production targets and prepare machine, workstation, and material-flow layouts to achieve the highest possible efficiency. Modern planning and layout-design tools can be used to develop an effective production setup.

  10. Monitoring factory performance in areas such as quality, delivery, cost, productivity, and target achievement, while working with internal teams to identify problems and implement corrective actions.

  11. Balancing manpower according to production requirements, establish achievable targets, and continuously monitor actual performance against those targets.

  12.   Eliminate waste by reducing non value-added activities and also unnecessary processes.

  13. Improve flow and reduce lead time by minimizing, waiting, WIP, and process delays

  14.  Drive continuous improvement (Kaizen) through regular problem-solving and various process improvement.

  15. Implement 5S to maintain a neat & clean, organized, safe, and efficient workplace.

Roles of Industrial Engineers in a garment Industry:

  1. Collect line loading plan from Planning Department.

  2. Attend PP meeting and discuss production requirements.

  3. Collect size set sample and prepare Operation Bulletin.

  4. Collect Operation Bulletin and prepare paper layout.

  5. Discuss machine, folder, attachment and technical issues with Maintenance and Technical team.

  6. Discuss floor layout with Floor In-charge according to paper layout.

  7. Prepare machine layout according to the approved paper layout.

  8. Monitor daily NPT and reduce machine breakdown time.

  9. Perform line balancing according to target and capacity study.

  10. Identify bottleneck process and immediately take necessary action.

  11. Conduct one-hour production study for required processes.

  12. Monitor daily production input and output.

  13. Set daily production targets and follow up achievement.

  14. Monitoring hourly production and take necessary action.

  15. Monitoring daily 5S activities on the production floor.

  16. Cross check thread consumption for every new style.

  17. Maintaining production efficiency at 65–70%.

  18. Design and improve workstations according to the process requirements.

  19. Improving operator motion by correcting unnecessary movements.

  20. Reducing worker absenteeism and operator turnover rate.

  21. Improving one-piece flow by reducing unnecessary WIP.

  22. Reducing line setting time and overall throughput time.

  23. Ensure proper manpower utilization by reducing unnecessary helping processes.

  24. Discuss critical style points with QC and operators during layout.

  25. Prepare daily Manpower and Machine reports.

  26. Improve and maintain the Cut-to-Ship ratio.

  27. Take necessary actions to reduce absenteeism and operator turnover.

Industrial Engineering Tools in Garments Industry:

1. Work Study & Method Study

  • Work Study

  • Method Study

  • Motion Study

  • Time Study

  • Work Measurement

  • Work Sampling

  • Motion Economy

  • Two-Hand Process Chart

  • Flow Process Chart

  • Operation Process Chart

  • Man-Machine Chart

2. Time & Standardization

  • SMV / SAM Calculation

  • Standard Time

  • Basic Time

  • Normal Time

  • Performance Rating

  • Allowance

  • Production Rate

  • PMTS

  • MTM

  • MOST

  • Standard Work

3. Production & Line Management

  • Operation Bulletin (OB)

  • Line Balancing

  • Capacity Study

  • Target Setting

  • Manpower Planning

  • Machine Requirement

  • Man-Machine Ratio

  • Bottleneck Analysis

  • WIP Analysis

  • Hourly Production Monitoring

  • Efficiency Calculation

  • Productivity Analysis

  • Capacity Utilization

4. Layout & Material Flow

  • Line Layout

  • Workstation Design

  • Plant Layout

  • Material Flow Analysis

  • SLP — Systematic Layout Planning

  • Machine Arrangement

  • Material Handling

  • Space Utilization

  • Flow Analysis

5. Problem-Solving & Quality Tools

  • 5 Why

  • Fishbone / Cause-and-Effect Diagram

  • Pareto Analysis

  • Check Sheet

  • Histogram

  • Scatter Diagram

  • Control Chart

  • Root Cause Analysis

  • PDCA

  • CAPA

  • Defect Analysis

6. Lean Manufacturing

  • 5S

  • Kaizen

  • Value Stream Mapping (VSM)

  • Waste Elimination

  • 7 Wastes / Muda

  • One-Piece Flow

  • Continuous Flow

  • Takt Time

  • Kanban

  • Just-in-Time (JIT)

  • Pull System

  • Visual Management

  • Standard Work

  • Poka-Yoke

  • SMED

  • QCO

  • TPM

  • Cellular Manufacturing

  • Line Balancing

  • Bottleneck Reduction

These are established Lean tools; IISE materials specifically include VSM, 5S, Kanban, one-piece flow, standard work, SMED, TPM, Poka-Yoke, visual management and Kaizen among Lean practices.

Garment-Specific IE Tools

For a garment IE professional, I would also include:

  • Operation Bulletin (OB)

  • SMV/SAM

  • Target Calculation

  • Line Loading

  • Line Balancing

  • Capacity Study

  • Machine Requirement

  • Manpower Requirement

  • Skill Matrix

  • Operator Allocation

  • Machine Layout

  • Workstation Design

  • Bottleneck Analysis

  • WIP Control

  • NPT Analysis

  • Hourly Production Analysis

  • Efficiency & Productivity Analysis

  • Thread Consumption

  • Cut-to-Ship Ratio

  • Line Setting

  • Changeover Analysis

  • Operator Performance Analysis

  • Man-Machine Ratio

  • Production Follow-up

Different Production Systems

1. Progressive Bundle System (PBS)

In this system, garments are produced in bundles. Each bundle moves from one operation to the next one, and operators generally perform a specific operation repeatedly.

2. Unit Production System (UPS)

In unit production system, individual garment pieces are moved from one workstation to another workstation using a conveyor or similar material handling system. This helps maintain a continuous production flow.

3. Modular Production System

A modular system divides the production line into small, flexible teams. Operators may perform multiple operations or process, allowing the team to respond quickly to style change or quickly layout, volume, and production requirements.

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