INDUSTRIAL ENGINEERING STUDY

Modular Production team in the Apparel Industry

noreply@blogger.com (IE) — Tue, 17 Jan 2017 17:10:00 +0000

it is well standard that manufacturers of customer goods all over the world are facing major new demands, as well as shorter product life-cycles and rising competition. In response, companies are reorganization and moving away from traditional process-center work practices in favors of concurrent engineering methods.
In exacting, design for manufacture has gained common recognition as a means of reducing production costs and lead times. However, the optimal design for manufacture is not easy to achieve using current-day work organization and business structures. So we have to build a Modular Production team in the Apparel Industry with Procedures, Responsibility, Rules, and authorities.

Team Responsibility

Team is responsible to report of Production and Quality to the Leader.

Team work together to achieve objectives (ensure quality and meeting cycle time / tackt time, as determined by the management. (Team must control their absenteeism level, productivity and quality in order to achieve their incentive).

Team must perform a complete task as described in their operations assignments unless is required by the team leader to support some other areas.

Incentive Pay is a result of group performance (quality, attendance and productivity).

Team must monitor all keys performance as determined by the management.

Team is responsible in sustaining 5S concept in all time.

Team is responsible to deliver only acceptable quality Garments.

Team Rules

Scissors are attached to the sewing machine, the wrist or to the table.

Team members are not allowed to remove the scissors off the sewing machine, the wrist or the table. If they do, scissors must be kept in designated area.

Threads must be trimmed after completing assigned operation by workers.

No one is allowed to walk with the scissor or keeping it in the pocket.

The Final checkers (Q.C.’s) are not allowed to carry a scissor with them or to fix a scissor in to the table. Long hanging thread is considered as defect and is returned to the SMO to trim.

In case of Quality problems, refer to quality at the source.

Management Policy:

The management is responsible of assuring manufacturing staffs comply with all roles and responsibility described in this manual.
The management is responsible for truly empowering the team.

Supervisor Role:

The supervisor is in charge of planning the production of the teams.

The supervisor must provide technical assistance to the team under the request of the leader.

The supervisor has the right to track the production amongst the teams without interfering with the members.

The supervisor has the right to verify the quality of finished products. In case of discrepancy, communication is limited with the leader.

The supervisor must conduct 5 minutes meeting with the leader about to assigning the task to the team for capability assurance by the team.

The supervisor must ensure all requirements related to item no. 1.8 are prepared and delivered to the team.

The supervisor is responsible in communicating the requirements of the team to the management.

Team Leader Role:

The leader is the principal contact of the team with the management.

The leader is the responsible to monitor the quality of first and last processes and the output. (Quality is the team responsibility)

The leader is in charge of the environment within the cell.

The leader is responsible to maintain the discipline of the team.

The leader is responsible to ensure the accuracy of reported data.

The leader provides help and assistance to the team members.

The leader is in charge of members assignments.

Team Authority:

The team has the rights to refuse, stop any production due to the following issues:

Nonadequate Machinery

Defected cuts pieces from the Cutting Department.

Size Labels and different shades Mixture

Missing information, materials and tools as described in item no. 1.8 .

The team has the rights to request a time study or follow-ups for certain operations where there is doubt of time accuracy (SMV) related to the target.

Meeting Structure:

Meeting must not be longer than 5 minutes and must be held inside the cell.

Assignments meeting at initial start up of new order and quality standards distribution. (Occasional)

Troubleshooting related to Quality problems when reject rate is out of order. (Occasional)

Internal attitude problems of module team (involves only leader and the concerned operator). (Occasional)

3 Minutes at end of the day for “SHINE” session. (Daily)

Performance meeting for 10 minutes to evaluate the overall performance of the week. (Weekly)

Requirements prior to initial orders start-up:

Before start the initial sewing, modular team should receive the following documents and items:

Trims card (original samples),
P.O. Sheets of the new style,
All Original Size labels,
All Original Hang Tags,
Green seal sample including hang tags and size labels approved by the Buyers/Merchandiser,
Measurement spec,
Critical Points instruction,
New quality record papers,
Sketch of measurement,
Operations bulletin with quality standards,
Work Load Orders (productivity target, Pitch time, days available, etc..)
Checklist orders quantity,
Pattern of the orders sizes and different parts,
Scrap fabric from the cutting room (same type as the style) for machineries adjustment,

Absenteeism coverage:

No strange labor would be added in case of absenteeism. No any other worker will added to the Module team incase of absenteeism. Absenteeism must be covered using the bump-Jump system of which an operator moves from her station to another station on the basis of the operations sequences till reaching another operator then her or him drops the bundle and return back to its original station. In case of original station is occupied by another operator (A), the replacement operator (A) will leave the station immediately and returns back to her or his original station or till reach another bundle through the process. However, if the factory has pool of special runners (multi-skilled jumpers) leader has the right to request temporarily replacement to cover up the absenteeism. For this purpose, leader communicates with the supervisor.

Skilled worker grading System of RMG

noreply@blogger.com (IE) — Sat, 14 Jan 2017 17:17:00 +0000

Generally workers are categorized as per there operating skilled. Some Workers are Multi Skilled, Semi-skilled and unskilled. skilled worker grading System most Important for Design a New Style Layout. Most of the Style Have Critical Operation which operation should be set Multi Skilled operator due to Quality Issue and Rejection Issue. skilled worker gradingSystem also need calculate for a line cost (CPM). In most of the factories operator’s salary is decided according to their grade level. So we should know about skilled worker grading System.

Let See the Classification of skilled worker grading System and remuneration:

Utility Operator.

Current

Propose

Identification – Scarf Color Yellow & Blue

Basic Salary ($) - New Grade

Expect Efficiency level - 60%

Should be able to operate any 04 machines out of 11 machine types mentioned in skill assessment document.

Should be able to handle any 10 operations mentioned under A, B & C in skill assessment document.

Senior Operator.

Current

Propose

Identification – Scarf Color Yellow

Basic Salary ($) -

Expect Efficiency level - 60%

Should be able to operate any 03 machines out of 11 machine types mentioned in skill assessment document.

Need the Capability to do any 8 operations mentioned under A, B & C in skill assessment document.

Operator.

Current

Proposed

Identification – Scarf Color Blue

Basic Salary ($) -

Expect Efficiency level - 60 %

Should be able to operate any 02 machines out of mentioned 11 machine types in skill assessment document.

Should have the capability to do any 5 operations mentioned under A, B & C in skill assessment document.

Junior Operator.

Current

Proposed

Identification – Scarf Color Light Blue

Basic Salary ($) -

Expect Efficiency level - 60 %

Should be able to operate any 01 machines out of mentioned 11 machine types in skill assessment document.

Should be able to do any 3 operations mentioned under A, B & C in skill assessment document.

Assistant Operator.

Current

Proposed

Identification – Scarf Color Burgundy

Basic Salary ($) -

Expect Efficiency level - 60 %

Should be able to operate any 01 of machines out of mentioned 11 machines types in skill assessment document.

Should be able to do any 2 operations of mentioned under groups A, B & C in skill assessment document.

Budgeted Cadre for Each Category:

Utility Operator if 8 line’s per unit.	Senior Operator.	Operator	Junior Operator.	Assistant Operator.	Total
8	7	15	12	5	39

Note – Line total operators -36 operators + 9 % absenteeism (3 operators)

Sewing Machine Operator Training Program

noreply@blogger.com (IE) — Sat, 14 Jan 2017 15:12:00 +0000

Training & Development represent a planned effort by an organization to facilitate employee learning of job related behaviors. Organizations spend billions each year on training. Training may occur in a variety of forms. The most common method is on the job training. In on the job training and experienced employee is asked to take a new employee under her or his wing and show the newcomer how to perform job duties. OJT has many advantages, such as few out of pocket costs for training facilities, materials, or instructor fees and easy transfer of learning back to the job. When implemented well , OJT is considered the fastest and most effective means of facilitating learning in the workplace. One type of on the job training involves moving people to various types of jobs within the organization, where they work with experienced employees to learn different tasks. This cross training may place an employee in a new position for as short as a few hours or for as long as a year, enabling the employee to develop new skills and giving the organization greater flexibility.

Now the time has come in Industrial Engineering to start developing workers giving them long awaited Training Program. It is recommended to start with machine operators we face low output in the sewing lines due to absenteeism and supervisors , managers found no / less people found in the sewing line to replaced the absent workers to perform as per the expected level. Here is no flexibility to balance the line properly to get the required out put. As such we lose in efficiency, quantity, quality and also delivery issues. Therefore we need to design a Sewing Machine Operator Training Program for Development There Skill. In this case we need to make this program very attractive for them. We lose our out put, efficiency etc when a person gets absent who works on a critical operations/ special machine/ can be both. So whatever training program design we need to keep these things in our mind. Also we can make this training program more attractive if it is linked with financial benefits. So we designed a training program identifying different skills , knowledge required for each grade and what will be the salary for each grade. We followed following steps to design the Sewing Machine Operator Training Program.

Step For Operator Skill Tanning Program:

1. Identify the critical operations.

2. Identify the minimum skill requirement for each line considering the items do in their line.

3. Maintain a skill inventory for each sewing line updating regularly.

4. Considering existing grades of operators, we can have 05 grades and those are Grade A1 = Utility, Grade A = Senior Operator, Grade B = Junior Operator, Grade C = Operator, Grade D = Assistant Operator.

5. After identifying the skill requirement we need to identify who are the people should go on skill upgrading.

6. Allocate experience worker/ coach of training school for her/ him to learn the work and in this instance need to do the formal work filling the required documents and signing by Senior Supervisor, Senior IE & Unit manager. This gives the approval to go head with the training.

7. When the worker gets the training Supervisor, IE, training school etc should follow the training.

8. Training period should be maximum 07 days.

9. After the training worker will get the chance to perform the same operation in the line.

10. If the worker achieve the expected efficiency (minimum 60%), quality &maintaining the right attitude she deserves a salary increment. This increment can be done monthly basis.

11. We have to do the training and salary increments keeping the budgeted cadre in our mind. E.G. One line can have following operators in each category.

Utility = per line one worker to balance the absenteeism. ( its not including to line cadre )

Senior Operators = 07 workers.

Operators = 15 workers.

Junior Operators = 12 workers.

Assistant Operator = 05 workers

12. Before the salary increment we need to follow the formalities by assessing the worker using the assessment form. Again this has to be sign by Supervisor, IE, UM HOU.

13. Signed documents should go to GMO for salary increment recommendation, then need Director

sir, approval to proceed with the payment. After all formalities documents should go the HRD to execute the payment.

New Trends for leadership development

noreply@blogger.com (IE) — Thu, 12 Jan 2017 17:08:00 +0000

Those come as a result of research that done by using 247 leaders from different Type of organizations and nations. Basically by New Trends giving information to leaders About barriers that there are creating and the way they should run the organization.

What are the New Trends?

The Rise of complex challenges.
The innovation Revolution.
The art of virtual Leadership.
Collaboration Nation.
The World of Interruption.
Authenticity is the next celebrity.
The Fallout from the baby boom.)
Leadership for longevity.
What’s next?

Discussion About New Trends

With the competition of the market and some other factors leaders has to face challengers Those are more complex and with more variables, due to the following reasons, complex Challengers can overcome.

Market Dynamics and competitive.
Talent Shortage.
Globalization and technological improvement.
Increase cost and less profit.
Higher customer expectation.
Time to time change internal process and policies

By analyzing, taking the decision with risk, navigating challengers Ect. Can minimize Effect of complex challenges.

The Innovation Revolution:

Because of innovation improvement organization can take high growth Rate and it will help to face day by day changing market competition. By this way Organization possible to reduce their manufacturing and service cost and increase there Product features and quality. By following way we can promote innovation improvements.

Talent development.
Rewards Programs.
Performance Metrics.
Consultants.
Action planning group.
By process improving.

The art of virtual Leadership

Because of many reason leader can’t convey their message properly, there are so Many communications channels to communicate their message, those areas follows.

General communications.
Frequent communications.
Time management.
Relationship building.
Honest Communications.
Emotional Intelligence.
Well Written / Clear

Effective Communication

To avoid communication errors and improve communication quality leaders can take the Following type of steps. Designing ways for the team to document and store its knowledge in a central location. Creating a guideline for when and how to communicate. Creating a Communication team to pass the relevant message to organizing manner.

Collaboration Nation:

Nowadays organizations looking for collaborated management team than skill one leader By collaboration can reduce management level gap with leaders and that will help to Make second layers leaders for future.

The World Of Interruption

Interruption is a main barriers for leaders to continue their work by giving concentrate To their work, but that is not totally unavoidable from the organization. But during the research They have identified by leaders comment, Those are as below:

Prioritize calendar maintain.
Use Executive Assistant.
Telecommute.
Limit emails.
Close door.
In Early / stay Late /Work Weekends.

Authenticity is the next celebrity:

Most of the leaders are not showing their authentic character to their workplace, Because of they have to maintain their “Executive image” among their team. Most of the leaders maintain two lifestyles for family and workplace. Due to the following Type of reason they are not able to maintain their authentic lifestyle.

Fear of negative outcome.
Politics.
Micro and macro environmental influencing factors.
Maintain Morale.
Resources.
Interpersonal dynamics with other leaders.
Organizational culture.
Awareness.

The Fallout from the baby boom

After the 2nd world war world got huge population growth rate and increase Employment and Different kind of skill levels.

Vision.
Knowledge.
External Personal Network.
Internal Personal Network.
Multi-skills.
Historical Context.

· Recommendation and Suggestions:

Strategic Marketing Activities improvement.

- Establish new, second brand for the low market approach (also new Products)
- Buy competitors,

- Franchising

- Use youth & college students for marketing factions.

- Giving part-time job opportunities to college boys.

Product Range

Moderate change
Redesign Menu
Localization of products
Healthy products
offer lunch

Radical change

- Slash prices/offer a low-end product range

- Leave traditional distribution channel and concentrate on
supermarket&

- Convenience store sales

- Refurbish stores to attract different generations of customers

- Do catering / delivery service.

Marketing Activities.

- Facebook ads,

- Festivals / Parties / Special offers (like McDonald’s Mexican or
Asian Weeks)

- Redesign internet presence increased online activities

- Image Campaigns (has also impact on employees)

- Use ads in the magazine and display banners at playground, Jim etc.

What is work study?

noreply@blogger.com (IE) — Sun, 01 Jan 2017 18:04:00 +0000

The garment manufacturing and exporting industry is facing heavy challenges due to various factors including global competition, manufacturing costs increase, labor attrition, less productivity/efficiency, etc. So overcoming those challenges our need Effective Word Study knowledge.

Work study is a generic team for those techniques particularly Method Study and work Measurement which are used in the examination of human work in all, it’s contents and which lead systematically to the investigation of all economy of the situation being reviewed in order to effect improvement.

Work study then aims at examining the way an activity is being carried out, simplifying or modifying the method of operation to reduce unnecessary or excess work, or the wasteful resources, and settling up time standard for performing the activity. The relation between productivity and work-study is thus obvious. If work study results in cutting down the time of performing a certain activity by some percentage (Minimum 20%).

As a result of rearranging the sequence or simplifying the method of operation and without additional expenditure, then productivity will go up.

Work Specifications

A work specification is a document setting out the details of an operation or job, how it is to be performed, the layout of the workplace, particulars of machines, tools and appliances to be used, and the duties and responsibilities of the worker. The standard time or allowed time assigned to the job is normally included.

Clarification of Work Study

1. Work Measurement 2. Method Study

1. Work Measurement: Measure the work content in the task.

2. Method Study: Systematic recording & critical examination of ways of doing things in order to make improvements & proposed way of doing works as a means developing & applying easier & more effective methods and reducing cost

Why do we need work study?

-It is a means of raising the productivity of a plant or operating unit by the reorganization of work, a method which normally involves little or no capital expenditure on facilities and equipment.

-It is systematic. This ensures that no factor affecting the efficiency of an operation is overlooked, whether in analyzing the original practices or in developing the new, and that all the facts about that operation are available.

-It is the most accurate means yet evolved of setting standards of performance, on which the effective planning and control of production depends.

-It can contribute to the improvement of safety and working condition at work by exposing hazardous operation and developing safe methods of performing operators.

-The savings resulting from properly applied work study start at once and continue as long as the operation continues in the improved form.

-It is a “tool” which can be applied everywhere. It can be used with success where ever work is done or plant is operated, not only in manufacturing shops but also in the office, stores, laboratories, and service industries such as wholesale and retail distribution and restaurants, and on farms.

-It is relatively and cheap and easy to apply.

-It is one of the most penetrating tools of investigation available to management. This makes it an excellent weapon for starting an attack on inefficiency in any organization since, in investigating one set of problems, the weaknesses of all the other functions affecting them will gradually be laid bare.

Basic Idea of Industrial Engineering

noreply@blogger.com (IE) — Sat, 31 Dec 2016 17:45:00 +0000

Industrial Engineering is concerned with the design, development and installation of an integrated system of man, machine and equipment drawing upon specialized knowledge and skill in the technical, economics and human sciences. Either with the values or methods of engineering analysis and design to specify, forecast and evaluate the results to be obtained from such a system.

Actually, Industrial Engineering is a Scientific Tools for logical examination of the methods of carrying on activities to progress the effective use of resources and to set up values of performance for the activities being carried out. The Other way “IE is a Scientific technique to examine all factors, which are affecting to the productivity”

The main value of IE at investigative the way an activity is being carried out, simplifying or modifying the system of function to reduce unnecessary or excess work, or the wasteful resources, and settling up time standard for performing the activity.

In the World Industrial Engineering (IE) most popular in Apparel Manufacturing (Garment’s Industry) for help to increase Productive and Efficiency.

Industrial Engineering are responsible for making sure that the best use is made of all resources, land and buildings, materials, machine and men. This can be achieved by coordinating the efforts to everyone in the organization to achieve the best results and to use the resources as effectively as possible.

Mostly IE concentrates in two areas, the time it takes to do the job (Work Measurement) and the best way to do the job (Method Study).

We can use IE Techniques to control resources. What are the main resources to be controlled?

please see the below list (there are):

Manpower

Machinery

Material

Method & Techniques

Land, Floor area

Etc.

The vision of industrial engineering:

“The Vision is to Improve the productivity of an organization and Make pleasant working environment through Systematic and Scientific Management Techniques”

Strategies:

1. Analyze the Entire process & working-out the required Capacity.

2. Doing the Floor drawing as per the required Capacity & working-out cost for renovations.

3. Identify the Required work-aids, doing the drawing of them & working out the cost for work aids.

4. Getting required Raw materials in housed.

5. Make the Sample for each work-aid & confirm the bulk.

6. Starting bulk.

7. Arrange the floor lay-out using made work-aids.

8. Starting the trial Run covering the specified system.