Roles of Industrial Engineering in Garments Factory

Roles of Industrial Engineering in Garments Factory

Industrial engineering (IE) plays a vital role in the apparel industry, that’s why Industrial engineering job roles are very important for garments factory. When we need to reduce cost and improve work efficiency in this competitive era, the apparel industry hires an Industrial Engineer to do that job smartly. Apparel manufacturing industry is growing quickly by applying IE in their facility. I this article I am giving a list of IE activities in garments factory which will help you to understand the Roles of Industrial Engineering in Garments Factory.

Roles of Industrial Engineering in Garments Factory

Objectives of Industrial Engineering (IE) in the Apparel Industry

  1. To increase productivity
  2. Process improvement by motion reducing.
  3. Reduce work in process (WIP) and remove the bottleneck.
  4. Increase efficiency of operations
  5. Reduce man machine ratio
  6. Process improvement to reduce cost, waste and rejection Reduce wastage and defects
  7. Fill up Key Performance Indicator (KPI) target.
  8. Keep workplace and environment safe
  9. Production planning and implementation
  10. Evaluate operator and staff performance, disciplinary matters, training needs, and their career development.
  11. Set the target and make a draft, layout design of the machine requirement, material flow, and workstation to bring the best possible efficiency. Modern tools are used to design of the layout.
  12. Monitor factory performance in terms of quality, delivery, cost-efficiency and target improvements with the internal factory team and taking necessary corrective action.
  13. Manpower balancing, target setting, and monitoring achievements.

Daily Activities and Duties of an Industrial Engineer in the Apparel Industry

  1. Collect line loading plan from the Planning Department
  2. Attend in Pre-Production (PP) meeting
  3. Collect size set sample and make operation bulletin accordingly.
  4. Collect Operation Bulletin and make a paper layout
  5. Discuss with Maintenance in-charge regarding machine, folder, attachment and Technical personnel for technical issues.
  6. Make discussion with a floor in-charge about layout according to paper layout
  7. Check Daily Non-productive time (NPT) and reduce machine breakdown time.
  8. Make layout according to paper layout
  9. Make line balancing according to target and capacity study during 2 – 3 days of layout
  10. Find out the bottleneck process and solve it
  11. If needed make 1-hour production study in required process
  12. Everyday input and output monitoring
  13. Give daily production target and follow up production achievement.
  14. Hourly production follow-up
  15. Everyday 5S related activities monitoring
  16. Cross check thread consumption for every new style.
  17. Ensure up to 65%-70% efficiency.
  18. Workstation design
  19. Operators motion development by correcting faulty motion.
  20. Reduce worker absenteeism and turnover rate
  21. 5 pcs flow by reducing WIP
  22. Reduce line setting time or throughput time.
  23. Proper utilization of manpower by reducing unnecessary helping process.
  24. Establish a meeting in-between QC and operators regarding critical points of the style while layout.
  25. Prepare daily Man/ Machine report
  26. Developing cut to ship ratio.
  27. Work to reduce absenteeism and operator turnover

Roles of Industrial Engineering in Garments Factory pdf

Written by

A.M. Amirul Islam (Washim)
Email: [email protected]

Linkedin: A.M. Amirul Islam

Job Responsibility of IE in Apparel Industry

Before appointing an industrial engineer for the apparel industry, you have to keep in mind the Job Responsibility of IE in Apparel Industry. Here IE means Industrial Engineering. The world has limited resources but day by day we need to produce more and more product. The challenge is to increase productivity by using the least amount of resources. Garments industry is very much competitive. So in this competitive industry, it is a big challenge for Bangladesh or any other country to survive. We are looking for a solution where we will get more productive technology with lower cost. Industrial Engineering is all about optimization of limited resources. Generally, Optimization, Planning, and Process Control is the core work in apparel for the industrial engineering department.

Job Responsibility of IE in Apparel Industry

Nowadays IE playing the key role in the apparel industry. Industrial Engineering Job is not an easy job, always engineers need to take on the challenge and bring a complete solution. The person who is responsible for industrial engineering is considered as an industrial engineer. I made a list of industrial engineering activities in the apparel industry.

Job Responsibility of IE in Apparel Industry

Major Work of Industrial Engineering in Garments

Industrial Engineering deals with the following activities:

  1. Time Study, Motion study
  2. Taking the capacity study of full-line and line balancing for clean-up bottleneck area.
  3. Methods developments & analysis as a side of quality & quantity.
  4. Follow-up the low performing Operators.
  5. Operation breakdown, Operation Bulleting / Layout
  6. SMV calculation by time study.
  7. Operator skill Summery.
  8. Train up production staff on efficiency.
  9. Process-wise operator skill development.
  10. Nonproductive time (Loss Time) record and reduce.
  11. Hourly Production Monitoring & Achieve the line Target.
  12. Prepare Man machine report.
  13. 5s implementation, Training, and Auditing
  14. Work on 7 QC tools to minimize defect.
  15. Statistical analysis for continuous quality improvement.
  16. Production Planning and control, Planning Calculations
  17. Capacity Study
  18. Production Study
  19. PDCA Cycle
  20. 7 Wastage reduce
  21. Manpower Budget Planning
  22. CPM, CM Calculation
  23. Line Cost Calculation, Floor capacity calculation
  24. SPM, EPM, PCL Calculation
  25. Reduce WIP (Work in Process)
  26. Operator, Line and floor efficiency Calculation
  27. Follow up KPI (Key Performance Indicator) and Report
  28. Inventory Control in all section
  29. Implementation lean manufacturing tools and Six Sigma
  30. Provide Incentive for operator and Production staffs
  31. Manpower requisition and set up
  32. Eliminating excess manpower
  33. Improving Productivity through detailed analysis of the process by process
  34. Smooth supply chain management from raw material to output
  35. Helping to launch the TQM (Total Quality Management) system in a factory
  36. Implement traffic light system on the floor & reduced sewing defect percentage
  37. Co-ordination with merchandising
  38. Fabric & thread consumption.
  39. Garments analysis & style development for reducing costing.

Please mention in the comment box if I missed any point.

Written by

A.M. Amirul Islam (Washim)

Facebook: Amirul Islam Washim

Phone:+8801929643301
E-mail: [email protected]