Industrial Engineering (IE) in Apparel industry
Industrial Engineering
Industrial Engineering is manufacturing engineering to increase productivity and quality. Here I have written about Industrial Engineering (IE) in the Apparel industry, job scope, job description, and basic IE works of the apparel industry.Industrial Engineering in Apparel industry
Apparel manufacturing factories are facing global competition for cost-saving, productivity, and quality improvement. Industrial Engineering is dealing with these factors to reach the highest level of productivity, quality with minimum waste. So an industrial engineer has a wonderful opportunity to contribute to the apparel manufacturing sector by implementing all engineering tools for the growth of this industry.IE team works in cutting, sewing, and finishing to reduce manpower and WIP, setting line Layout (operation breakdown) increase work efficiency, productivity, Demand forecasting, develop a new design, Develop Layout, Work with different quality tools, Bend product and seasoning development, Efficiency, Wages and earning calculation, CNC machine operation, Scheduling, Capacity analysis, Line balancing, Kaizen, Kanban, Production planning, Calculate NPT, Bottleneck removing, etc. . They analyze CM, SMV, costing, consumption, profit- Loss. Good IE teams make a good efficient factory. They also follow up daily production targets and production achievement being responsible for production, working in the sewing line if there is any bottleneck. Generally, Textile engineer, IPE engineer, and other academic background work in Garments IE department, career growth is very quick here. After merchandising, all textile graduates go for IE jobs in a Garments factory. Starting a career in IE department is not very easy, there is a challenge too and pressure to fill up the production target of assigned sewing lines. After reaching one stage, your job will give you comfort to be followed up work sitting in own desk. This is the era of the 4th industrial revolution where people go innovative ways to increase the growth of productivity.
The importance of industrial engineering in Garments industry
When garments manufacturers had faced a threat of global competition, other manufacturers produced products at a lower cost; the garments industry started to set industrial engineering to produce more goods at a lower cost. Industrial engineering works to produce maximum output by limited minimum resources and every action taken to calculate what adds value to the product.IE jobs in Garments industry:
Career start in IE department as IE officer, growth faster than any other department in the apparel manufacturing industry. There are many jobs out there in IE department. In recent times garment industries hiring many employees to work for engineering development in their facilities. Job designations are IE officer, executive, senior executive, assistant manager, manager, head of IE, AGM/DGM/GMYou may like to read: IE interview questions and answer of apparel industry
Basic knowledge doing IE job in Garments
Basic knowledge is about Industrial
engineering such as efficiency, production, productivity, overall efficiency,
on standard efficiency. Major KPI such as man to machine ratio, cut to ship
ratio, order to ship ratio, on-time delivery percentage, average style
changeover time, DHU, quality to the production, NPT, the major area of NPT.
Skill matrix, what are the criteria of operator grading. Thread consumption,
elastic, lace consumption knowledge. Identify bottleneck and eradicate
bottleneck. Knowledge about stitches. making operation bulletin. Working under
pressure and cope up with every situation. Well dress up and finally be smart.
English knowledge is very important cause a lot of foreigners are working in this
section. Mathematical knowledge such as CM, CPM, EPM, efficiency, rating.
Knowledge about lean, 6S, kaizen, kanban, 6M,7M,8M.etc.As an IE we have a lot
of responsibility. Have knowledge about IE like Manpower optimization,
studying line capacity & production study, Layout setting, Analysis of
method & trying to improve the process, finding bottleneck &line
balancing and Target setting, Consumption of Elastic, piping & many things.
The job responsibilities of IE officer /executive /Manager have to do in Garments Industry
1.
Ensure
Operation Bulletin (OB) and re-engineering or balancing the bulletin for better
productivity in sewing and finishing
2.
Measuring
accurate factory efficiency, line performance, changeover effectiveness,
capacity study, time & motion study, machine breakdown, etc.
3. Carry out pre-order costing and post-order costing (artwork & sample) in coordination
with merchandising team.
4.
Set
up base target based on basic, semi-critical & critical operations and
ensure the implementation of line and special incentive policy.
5.
Set
up SOP, process Flow chart & process re-engineering to improve the
different processes.
6.
Conduct
skill assessment of new operators, ensure floor discipline, identify training
needs and manage their work quality and career development.
7.
Optimum
of utilization Man, Machine & Method (3M).
8.
Communicate
with the product development team to make the product feasible for production,
and at the same time, meet customers' demands.
9.
Analyze
productivity and improve the system by implementing kaizen and innovation in
the process.
10.
Prepare
monthly manpower projection, requirement, and turnover
11.
Ensure
cost reduction by reducing all kinds of wastages.
12.
Ensure
safety, quality, and compliance activities in the workplace.
13.
Monitoring
Production Schedule.
14.
Studying
and implementing time study, method study, etc
15.
Strategic
Project Planning.
16.
Analyzing
the DFMEA & Process FMEA.
17.
Monitoring
Worker Ergonomics design for better posture
18.
SMV
(Standard Minutes Value), Efficiency calculation and assigned a Target based on
efficiency and SMV.
19.
Six
sigma Implementation Using DMAIC approach.
20.
Adopt
industrial engineering practice in every possible area for maximum productivity
and ensure optimum utilization of resources & implementation of QCO.
21.
To
calculate SAM by both rating method & GSD (TMIS) method
22.
Have
clear Knowledge about TMIS, TMIS coding system
23.
Have
sound knowledge about Motion analysis by showing Video with TMIS software
24.
Clear
knowledge of Lean tools: Kanban, Kaizen, TPM, 5S, Yamazumi Chart.
25.
Good
in designing production equipment/tools considering Ergonomics
26.
Establish
lean manufacturing culture to reduce non-value-added processes.
27.
Innovate,
update and implement procedures for IE
28.
Making
Layout of the machine with manpower distribution by maintaining proper sequence of
sewing operations to ensure the best workflow.
29.
Set
up and manage the Training Centre for trainee operators, cooperate with HR for skill
test in recruitment, manage the skill
assessment scheme for all production operators.
30.
Good
team player & high adaptability in any situation
31.
To
Implement IE tools & techniques in the Factory.
32.
Study
and record time, motion, method, and speed involved in the performance of
production and other worker operations using GSD tools and techniques.
33.
Supply
the costing SMV information to merchandising team for costing purposes.
34.
Thread
consumption
35.
Set
the target and draft and design layout of machine, materials, Prepare layout
for the floor for effective utilization of men, machine, and material.
36.
Bottleneck
solving
37.
Line
Balancing
38.
Individual
orders follow up.
39.
WPR
Report making.
40.
Capacity
Booking & Open Capacity Plan as per factory business plan.
41.
Check
the cutting production; sewing production; Finishing production; absenteeism;
cutting balance, Loss time monitoring report; Efficiency and compile reports on the progress of work and production problems.
42.
Cut
panel Rejection analysis report.
43.
GSM
high low monitoring report in cutting section.
44.
Shade
checking report in cutting section.
45.
Excess
fabric handover to store from cutting report.
46.
Prepare
skill inventory for the operator.
47.
Arrange
technical and pre-production meetings with production, Quality, Merchandising, and PD team before new style/input are given in line.
48.
Line
Loading Plan
49.
Maintaining
Master file from Cutting to packing all production data.
50.
KPI
report, follow up and yearly presentation
51. To
monitor Target Vs Achievement KPI.
52.
Implementing
Lean tools (5S, Kaizen, Kanban) in different workplaces. (Administrative office
area, QC room, Yarn Store, Cutting)
53.
Implementing
different types of production & quality SOP’s on the production floor (Cutting,
Sewing, and Finishing).
54. Follow-up finishing WIP (From input to Packing).
55.
Maintaining
Left Over status report. Updated with ERP (ALGO ERP, LOGIC ERP).
56.
To
Make Daily Production Report as Per Production on Which the Salary of Operators
is Made.
57.
Making
Cutting Report According to PO Based on Which Cutting Team Ensures Cutting.
58.
To
Generate Daily Sewing WIP Report According to File, PO, Style & Color Based
on Which The Production Team Runs Sewing.
59.
To
Make Daily Finishing WIP Report According to Color Based on Which Finishing
Team Runs Finishing.
60.
Generating
Running Order Status Daily According to File, PO, and Style & Color for
Understanding the Order Status.
61.
To
Make WIP Reduction Report on Which WIP & Production Progress Can Be Known.
62.
To
Make Washing Report Based on Which Items Are Sending for Washing.
63.
To
Generate Packing Report on Which CT-PAT Continues Their Packing Activities.
64.
To
Generate Shipment Update for The Betterment of Proper Follow Up of Shipment.
65.
To
Generate Critical Shipment Follow Up for Especially Critical Shipment According
to Every Style & Ensuring Follow Up Strictly.
66.
To
Make Reconciliation After Delivery of Every Shipment for The Illustration of
Every Shipment According to File, PO, Style & Color.
67.
Through
Generating Cut Plan Follow-up Report, Strictly Ensuring Follow Up the Cut Plan
for Cutting the Fabrics on Time. Make and evaluate cut to ship ratio report
68.
Accumulating
Data of all sewing Lines of all Units, Making Consolidated reports &
Variance reports, and Mailing to top management.
69.
Identifying
the Causes of Variance between Build Up & Actual Production and Solving the
Problems through Proper Collaboration with HOO, DGM-GM & Concerned Persons.
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