What is Industrial Engineering?
Industrial engineering is a branch of engineering which studies the design and operation of production and service systems and the people who operate in these systems. Industrial engineering helps to improve quality and productivity. It is said that without industrial engineering operations is like meal without salt and if you use operation management instead of production management it will be best. Roles of industrial engineer in apparel industry is huge because IE works for reducing cost & improve work efficiency in the textile and apparel industry.
We can see at a glance of IE,
Industrial Engineering (IE) = Production ↑ Cost ↓ Proper run of all elements ↑ Efficiency ↑ Profit ↑
Some Industrial Engineering Formulas for Textile professionals:
Some of important formulas of industrial engineering are given below for textile students as well as professionals.
1. Average time (in minute) = (Sum of average)/(Number of observation) ÷ 60
2. Normal time = Average cycle time × Rating.
3. SMV = Observe time × Rating + Allowance.
4. Individual OP efficiency = (Total output ×Operation SMV)/(Total working minute) × 100
5. Efficiency % = (Total production × SMV)/(Total working minute × Total manpower) × 100
6. Performance = (Total production X SMV)/((Manpower ×Total working minute)-Loss time) × 100
7. Efficiency Improvement = (During intervention efficiency – Base line efficiency)/(Base line efficiency) × 100
8. Total labor cost saved per line = Extra minute produce × cost per SAM.
9. Worker potential production per hour = 60/(Basic minute value)
11. Line target per hour = 60/SMV × (Manpower × Wanted efficiency)
12. Defect of hundred unit (DHU) = (Total no of defect unit)/(Total inspection unit) × 100
13. Defective % = (Total no of defect unit)/(Total inspection unit) × 100
14. Productivity each person per hour = (Total output)/(Total worker ×Total working minute) × 100
15. Machine productivity = (Total units produce by the line)/(Total no of machine use to produce those garments)
16. Basic pitch time = (Total SMV)/(Total manpower)
17. Upper control limit = (Basic pitch time )/(Wanted organization efficiency)
18. Lower control limit = (Basic pitch time × 2) – Upper control limit
19. Cut of ship loss % = (Total cut quantity – Total ship quantity )/(Total cut quantity) × 100
20. Cut of ship ratio = (Total shipped quantity )/(Total cut quantity) × 100
21. Cut of ship ratio improvement % = (New cut to ship ratio – Base line ratio)/(Base line ratio) × 100
22. Receive to ship ratio = (Total ship quantity )/(Total fabric receive for the order (Sq.yds)) × 100
23. Total financial saving = Number of extra pieces shipped × Average FOB
24. Cost Per Minute (CPM) = (Average expenditure of the factory )/(Average Produce time (Monthly) )
25. Cost of Manufacture (CM) = SMV × CPM
26. CM earned per person per hour = (Total output × CM per garments )/(Total worker × Total working minute)
27. Monetary Loss due to cut ship loss in month = (Total number of produced garments in month × cut to ship loss percentage for a month × Average FOB of the style)
28. Monetary Loss due to cut ship loss in style wise = (Total number of produced garments in the style × cut to ship loss percentage for a month × Average FOB of the style)
29. Man & machine ratio = (Total manpower)/(Total machine)
30. Audit fail % = (Total no of audit fail)/(Total no of audit) × 100
31. Earned minute = Total production X SAM
32. Factory direct & indirect ratio = (Total headcount – No of machine operators )/(Total no of operators)
33. Labor cost per minute = (Total salary of the labor in the month)/(Total SAM produce by those labors in that month)
34. Estimated production per hour = (No of machine assigned × Hourly target qty)/(Calculated no of machines)
35. Estimated machine productivity = (Total minute in a shift × Line efficiency)/(Garments SMV)
36. Productivity Gap % = (Worker potential production P.H – Current production pcs P.H)/(Current production pcs per hour) × 100
Founder & Editor of Textile Learner. He is a Textile Consultant, Blogger & Entrepreneur. He is working as a textile consultant in several local and international companies. He is also a contributor of Wikipedia.
