IE DEPARTMENT

Objective of the department

The IED department has to work with many other departments as this department gives
the entire idea of the garment construction and the thread and trims consumption criteria,
operators skill level categorization and other related aspects hence they play a vital role in
determining the cost of producing a single piece of the garment and they also calculate
the cost of the factory for that particular style of garment.
Functioning of the department.
The IED department helps the planning department to know the time required for the
production of that particular style of the garment by calculating the SAM value for it and
they also help in knowing the capacity of the factory based on which the planning
department takes a decision if they have to proceed with the item or no.
The IED calculates the SAM value for the garment, calculates the productivity of the
given style for the initial costing and also calculates or counts the accessories
consumption by the style and gives all these details to the merchandising department for
the costing purpose because the entire costing criteria depends on these aspects and the
IED also gives the merchants suggestions regarding the reduction of the cost of
manufacturing the garment by modifying any of the steps and the method of doing it.
The IED people prepare the style bulletin which includes the different types of seams and
stitches that has to be done for the garment and it also includes the length of the seams
and the types of stitches that has to be carried out at different places of the garment as per
the buyer’s specifications and approval. Types of thread (which is the TEX), area of
placement of the trims and accessories and its location different kinds of labels that are
supposed to be placed, the criteria under which the finished garment has to be checked,
the times at which the inspection has to be carried out will also be mentioned in the style
bulletin, this bulletin will be similar to the Tech Pack but contains more technical data
than that.

This department will analyze and estimate the manpower and their skill level which is
required for the production of the garment, they also set a target to the batch for an hour,
for a shift and for a month which will help them to maintain their outputs and also helps
in timely completion of the order or sometimes earlier. They will also give the target to
each operator based on his/her capacity and skill in order to help them finish their piece
of work on time and also maintain the quality of their work.

After setting the targets for a batch and also for each operator then they will calculate the
efficiency. This efficiency is purely based on the daily output of the batch as well as the
single operator and then they come up with the monthly output by the particular batch.

This department maintains a file which is the DPR (Daily Production Report), in this
report they update the batch number, style/item number, actual output, committed output,
SAM value of the garment (both actual and that particular days SAM value), total
production till date, average efficiency of the batch till date, peak efficiency achieved, if
the company was working that day or not, if there was a delay of production then the
reason behind it, information about the batch setting prior to the mass production, etc., all
this will be mentioned in this DPR.

Based on the operator’s performance which would have been observed for a specified
period of time, the department will allocate a grade to the operator which is as follows.

Skill type Grade

A Highly skilled
B Skilled
C Semi skilled

The operators for each batch are taken in a ratio of,

20% - Highly Skilled
25% - Skilled
55% - Semi skilled

This is done irrespective to any style and buyer and the complication of the style.
A record is maintained in which the skills of operators are updated on timely bases.
Because of maintaining this record they keep in track of the operator’s skill and his
efficiency, working method and after a particular span of time they update the record.
Suppose a new operator joins and he is completely unaware of stitching then a training
for about 45 – 50 days is given to him/her and then based on their learning and grasping
capacity a grade is been allocated to them primarily. Suppose the operator/new employee
knows or has a previous work experience in a garment industry then he is just been asked
about his job which he/she would have done in the previous factory and then he/she is
just given an hour’s test to know his skills and then grade is been allocated.

Every day the IED team there will be a meeting where in which they speak about the
maintenance of efficiency of the batch in the production floor. They also conduct a
production review meetings with the operation team in which they discuss about the line
and the operation carried out in the batch suppose the previously planned flow is not
giving the estimated efficiency and output then they will think of changing the line plan
and review it and later follow the right one.
 PROCESS FLOW OF IED

Start

Pre-production Production Training new Fixing grade of

activities department trainees operators

Preparing operation
bulletin

Calculate
accessories
consumption
Hourly production tracking

Reducing bottleneck
operations by proper line
balancing

Capacity study

Efficiency calculations

End
 MAINTENANCE PROCESS FLOW

IE department sets the OB

and list of attachments.

Maintenance department looks for the availability of the work aid, attachments and the
machinery requirement in-house or otherwise order them to the supplier

Regularly keeps an update on the needle breaks and their causes so that it can be rectified
in the near future

Keep the machines in running

condition

Keeps a record of all the attachments used for the particular style for future reference in
case the style repeats
 Make each departments objective and with
current statutes with targets and give the giving
responsibility.

Example . IE

Objective Time and Action plan Responsible Current status. Target

Target date

1. Factory lost time reducing *machine back reduce.

*WIP controlling IE manager 10hrs /day
1/day

IE DEPARTMENT

IE MANAGER – RESPONSIBILITY

Responsible for achieving departments’ objectives and weekly, monthly has to review the
objective and take corrective and preventive action for achieving objective.

 Reduce the man to machine ratio.

 Maintain control & improve the factory efficiency.

 Guide the ie’s to achieve factory productivity & efficiency.

 Plan the production schedule for future month with f.m & s.p.m.

 Support to p.m & q.a.m to overcome production & quality issues.

  Initiate reducing sam values.

 Sitting with ie’s for operation breakdowns.

 Machine planning.

 Training & educate ie’s & supervisor.

 Conducting p.p meetings.

 Monitoring lost time & taking corrective action.

 Conducting monthly performers’ review meeting, with s.p.m & f.m.s.

 Conducting weekly review meeting with ie’s.

 Cost the garment (as per sample/sketch).

IE Departments Objectives.

1. Maintain the factory productivity and efficiency.

2. Reduce the minute cost of the factory.

3. Introducing the new technology to improved the SAM value and productivity

IE Manager – Responsibility

 .Maintain control & improve the factory efficiency.

 Guide the IE’s to achieve factory productivity & efficiency.
 Plan the production schedule for future month with factory manager & senior
production manager
 Support to production manager & Quality assurance manager to overcome
production & quality issues.
 Initiate reducing SAM values and reduce the man to machine ratio.
 Go though the operation breakdowns with IE’S.
 Machine planning.
 Training & educate IE’s & supervisor to achieve the company goals.
 Conducting pre production meetings with operation team.
 Monitoring lost time & taking corrective and preventive actions.
 Conducting monthly performs review meeting, with senior production manager&
factory manager.
 Conducting weekly review meeting with IE’s take necessary action to chive the
garget.
 Cost the garment (as per sample/sketch).
 Motivate the IE for achieving department’s objectives.
 Responsible for the welfare of all the people in the IE department

IE’s Responsibility

 Prepare the operation back down and layout for new style.
 Prepare thread consumption for new style.
 Plan the daily production as per SAM and maintain factory efficiency.
 Maintain factory efficiency as per plan.
 Line balancing and solving the bottle neck
 Maintain skill inventory.
 Save SAM by introducing new methods and technology.
 Training operators according to GSD or CMA methods.
 Prepare feeding plan.
 Prepare machine & attachment requirement before feeding.
 Cross check all the requirements are filling before loading.
 Guiding and helping to supervisor for achieving production target.
 Helping production manager and supervisor when technical problem arrives.
  Maintain systems and procedures and implementation new system for
improvements the factory.
 Reduce SAM by using work place methods.
 Reduce the lost time and take corrective action.
 Conducting pre-production meeting for line.
 Monitoring incentive & motivate operators & supervisors.

Production Departments objectives.

1. Achieve the monthly production plan.

 2. Onetime delivery.
3. Minimizing the damage percentage and second percentage.

Production Manager Responsibility

 Discuss the monthly production plan with senior production manager &IE manager.
 Monitoring hourly production, efficiency & performers.
 Monitoring the send wash & reconciliation.
 Attend the production, quality & technical issues.
 Attend to monthly perform review meeting.
 Attend to weekly quality meeting.
 Arrange machinery & attachment according to IE department requirement.
 Monitoring operators & workers turn over.
 Get involve for absentees, requirements & training.
 Follow the system & keep the floor in- charge & supervisor motivation.
 Motivate the subordinators to achieve the objective and tags.
 Responsible for the welfare of all the people in the Production department

F.M Responsibility

 Planning & preparing monthly order plan with P.M., QAM and IE manager.
 Participate monthly performers review meeting.
 Attend to weekly quality meeting.
 Attend to pp meeting & keep review meeting for middle management.
 Arrange machinery, attachments according to IE department requirement before
production.
 Co-ordination with merchandisers.
 Follow up reconciliation, shipments, production issues, quality & technical issues.
  Follow up cutting, input & accessories requirements.
 Follow up system & keep managers motivation.
 Follow up absentees, turn over & requirements.
 Handle the buyers’ requirement & customers complaint.
 Monitoring house keeper & safety procedures.

Floor in charge responsibility

 Follow up the production plan according to production manager.

 Involve to get production & efficiency with the quality requirement.
 Check the machinery & attachments before start production.
 Check the all accessories before start production.
 Educate & motivate supervisor & operator.
 Support to overcome production/technical & quality issues.
 Operator balancing.
 Tally with the cut quantity & hand over to send wash.
 Monitoring hourly production.
 Monitoring house keeping.

Supervisor responsibility

 Take the plan line output with efficiency.

 Get support from floor in-charge to balance the operation.
 Get support for IE to overcome bottle necks.
 Feeding the line.
 Attend to the highlighted quality issues & take corrective action.
 Educate & motivate operators.
 Monitoring the hourly production of individual operators.
 Monitoring rework hourly basic & rectify.

Quality Departments Objective.

1. Achieve the customer quality requirements.

2. Make system driven factory.
 3. Reduce the factory second rate.

Quality Assurance Manager Responsibility

 Planning and reducing the quality cost of the factory.

 Follow up and monitor the quality systems and procedures of the factory.
 Handle the buyer and buyer QA’s.
 Make sure final inspection pass on time.
 Attend & control factory defect percentage, second’s percentage and orders
reconciliations.
 Attend to the factory quality issues and take corrective and preventive actions.
 Conducting quality review meetings and take necessary action for improving the
quality.
 Attend customer complaint & get corrective and preventive action.
 Educate & motivate QA & QA supervisors.
 Monitoring the system & improve.
 Attend to pre production meeting & educate QA Ex, QA supervisor according to
buyer’s comments.
 Responsible for the quality of merchandise of the entire factory.
 Responsible for ensuring smooth and efficient working of the entire quality
assurance department.
 Monitoring quality assurance / quality control procedures on a daily basis and
taking corrective action and preventive actions as and when required in case of
deviations.
 Responsible for bringing about any change required in the quality systems
prevalent in the factory.
 Ensuring daily quality reports are generated and the quality assurance heads and
the findings for the day make audits discussed.
 Responsible for the welfare of all the people in the quality assurance department

Quality assurance Executive Responsibility.

  Study the sample completely with the tech pack to understand the technical
points, critical quality points /critical defects.
 Check whether all trims & accessories are using as per required & cross check with
the trim card.
 Attend the pre production meeting & get the comments & instructions.
 Educate the QA’s & checkers before new style starts.
 Follow up the 7/0 system , check reports , finishing defect report hourly basic.
 Take necessary action to keep the quality standard.
 Assist the inline QA’s when they have quality issue immediately & in effective
manner.
 Make sure all audit to be pass.
 Check all reports & discuss with QA manager daily basic.
 Make sure that all measurements / operations are provided with mock -ups.
 Educate AQ’s & checkers to achieve the quality standards.
 If you have any major issues, get the assistance from the Quality assurance
manager.

Quality Assurance Supervisor responsibility

 Discuss with QA executive about new style, along, sample, tech pack, & trim
card, to avoid quality problems. (Critical and non critical should be discuss &
decide)..
 Cross check all the trims & accessories with approved trim card.
 Follow 7/0 system with traffic light according to instructions.
 Prepare the mock up for each operation, which helps operators know about
quality standard & requirement.
 First out put pieces compare with the original sample & comments to make sure no
different in construction or appearance etc.
 Make the measurement of all size s which is running in line ( at least 10 pcs per
day ).
 Monitor all the check points & reports on hourly basic & take necessary to
achieve to reduce % with QA executive.
 Educate line checkers to reduce finishing defect %.
 While inspection if you found any major issues, get the assistance from the line
QA executive.
Cutting Departments Objectives

1. Optimizing the fabric usage.

2. Accurate and quality cut panel supply to sewing section on time.

3. Maintaining the cutting efficiency level.

4.

Cutting manager responsibility

 Make the cutting department plan according to the monthly order plan of the
factory and achieve the factory plan.
 Attend & solve cutting section production, technical & quality issues.
 Attend to p.p meeting, Educate and sharing the information that discussed in the pp
meeting to subordinators.
 Educate & motivate cutting works for achieving department’s objectives.
  Monitoring cutting system and procedures.
 Co ordinate with merchandiser, cad department, fabric department, pattern
department for information.

Cutting IE Responsibility

 Plan the monthly cutting production with Factory manager, senior production
manager and cutting manager.
 Plan daily product plan with cutting manager & follow up.
 Follow up the procedure & system.
 Co-ordinate with merchandiser department, fabric department, cad department &
pattern department.
 Get the assist any emergency from factory manager, senior production manager
.Quality assurance manager merchandiser.
 Help cutting manager to achieve daily target.

Finishing Departments Objectives.

1. Onetime delivery quality delivery.

2. Eliminate the packing violations.

3.Mtaintain the productivity and efficiency.

Finishing manager responsibility

 Follow up monthly dispatch plan.

 Monitoring the target hourly basic.
 Co-ordinate the shipments with buy’s QA’s.
 Attend to production & quality issues.
 Follow up the system.
 Keep the working place neet & clean.
 Make sure all reconsilation happen before shipments.
 Educate & monitoring all supervisor & workers.
 Any issues assist f.m, s.p.m & q.a.m.
QUALITY ASSURANCE MANAGER.

IE’S RESPONSIBILITY

 Prepare the ob & lay outs.

 Prepare thread consumption.

 Plan the daily production as per sam.

 Maintain factory efficiency as per plan.

 Line balancing.

 Solving bottle necks.

 Maintain skill inventory.

 Save sam by introducing new methods.

 Training operators according to gsd or cma methods.

 Prepare feeding plan.

 Prepare machine & attachment requirement before feeding.

 Cross check all the requirements are fill before loading.

 Help supervisor to achieve target.

 Help p.m & supervisor when technical problem arrives.

 Maintain systems & recommendation improvements.

 Reduce sam by using work place methods.

 Maintain lost time & do corrective action.

 Conducting p.p meeting for line.

 Monitoring insentive & motivate operators & supervisors.

pm’s responsibility

 Discuss the monthly production plan with s.p.m & ie manager.

 Monitoring hourly production , efficiency & performers.

 Monitoring the send wash & reconsilation.

 Attend the production, quality & technical issues.

 Attend to monthly perform review meeting.

 Attend to weekly quality meeting.

 Arrange machinery & attachment according to ie department requirement.

 Monitoring operators & workers turn over.

 Get involve for absenties, recurements & training.

 Follow the system & keep the floor incharge & supervisor motivation.
 s.p.m responsibility

 Planning & preparing monthly order plan with f.m & ie

manager.

 Participate monthly performers review meeting.

 Attend to weekly quality meeting.

 Attend to pp meeting & keep review meeting for middle

management.

 Arrange machinery, attachments according to ie department

requirement before production.

 Co-ordination with merchandisers.

 Follow up reconsilation, shipments, production issues,

quality & technical issues.

 Follow up cutting, input & accessories requirements.

 Follow up system & keep managers motivation.

 Follow up absenties, turn over & recurement.

 Handle the buyers requirement & customers complaint.

 Monitoring house keeper & safety procedures.

Q.a. exicutive responsibility

 Study the sample completely with the teck pack to under

stand the technical points , critical quality points /critical

defects.
 Check whether all trims & accessories are using as per
required & cross check with the trim card.

 Attend the p.p.meeting & get the comments & instructions.

 Educate the qa’s & checkers before new style starts.

 Follow up the 7/0 system , check reports , finishing defect

report hourly basic.

 Take necessary action to keep the quality standard.

 Assist the inline qa’s when they have quality issue

immediately & in efective manner.

 Make sure all audit to be pass.

 Check all reports & discuss with q.a.manager daily basic.

 Make sure that all measurements / operations are provided

with mouck ups.

 Educate qa’s & checkers to achieve the quality standards.

 If you have any major issues, get the assistance from the
q.a.manager.
 Q.a.supervisor responsibility

 Discuss with q.a.executive about new style , along , sample ,

teck pack , & trim card , to avoid quality problems. ( critical

& non critical should be discuss & deside )..

 Cross check all the trims & accessories with approved trim
card.

 Follow 7/0 system with traffic light according to

instructions.

 Prepare the mouck up for each operations , which helps

operators know about quality standard & requirement.
 1st out put pcs compare with the original sample & comments to make sure no
different in construction or appearance etc.

 Make the measurement of all size s which is running in line

( at least 10 pcs per day ).

 Monitor all the check points & reports on hourly basic &
take necessary to achieve to reduce % with q.a.executive.

 Educate line checkers to reduse finishing defect %.

 During your visit , if you found any major issues, get the
assistance from the line q.a.executive.

q.a.m responsibility

 Plan & reduce the quality cost.

 Follow up & monitor the quality procedure.

  Handle the buyer & buyer q.a’s.

 Make sure final inspection pass on time.

 Attend & control factory defect %, seconds % &

reconsilation.

 Attend to the factory quality issues.

 Conducting quality review meetings.

 Attend customer complaint & get corrective action.

 Educate & motivate q.a & q.a.supervisors.

 Monitoring the system & improve.

 Attend to p.p meeting & educate q.a.ex, q.a.supervisor

according to buyer’s comments.
 Responsible for the quality of merchandise of the entire factory.
 Responsible for ensuring smooth and efficient working of the entire quality assurance
department.
 Monitoring quality assurance / quality control procedures on a daily basis and taking
corrective action as and when required in case of deviations.
 Responsible for bringing about any change required in the quality systems prevalent
in the factory.
 Ensuring daily quality reports are generated and the quality assurance heads and the
findings for the day make audits discussed.
 Responsible for the welfare of all the people in the quality assurance department


floor incharge responsibility

 Follow up the production plan according to p.m.

 Involve to get production & efficiency with the quality

requirement.

 Check the machinery & attachments before start production.

 Check the all accessories before start production.

 Educate & motivate supervisor & operator.

 Support to overcome production/technical & quality issues.

 Operator balancing.

 Tally with the cut quantity & hand over to send wash.

 Monitoring hourly production.

 Monitoring house keeping.

 Supervisor responsibility

 Take the plan line output with efficiency.

 Get support from floor in-charge to balance the operation.

 Get support for ie to overcome bottle necks.

 Feeding the line.

 Attend to the highlighted quality issues & take corrective

action.

 Educate & motivate operators.

 Monitoring the hourly production of individual operators.

 Monitoring rework hourly basic & rectify.

THE IDEA SMITH

STANDARD OPERATING
PROCEDURE

INDUSTRIAL ENGINEERING
DEPARTMENT
Prepared by Approved by Issued by
Date Date Date

INDEX
DOC NO NO TITLE No of
Pages
SOP-UNT-IE 1 Cover 1

SOP-UNT-IE-IDX 2 Index 1

SOP-UNT-IE-1 3 Function Of IE department 1

SOP-UNT-IE-2 4 Organization Structure 1

SOP-UNT-IE -3 5 Duties and Responsibilities 2

of Each Position

SOP-UNT-IE-4 6 FLOW CHART 1

SOP-UNT-IE-5 7 Procedure 2
 1 FUNCTION OF IE DEPARTMENT

Industrial engineers determine the most effective ways for an

organization to use the basic factors of production – Man,
Machines, Materials, information, and energy - to make
or process a product or produce a service.

They are the bridge between management goals and

operational performance.
2 ORGANIZATION STRUCTURE
 IE HEAD

Sr. INDUSTRIAL
LEAN OFFICER
ENGINEER

JR. INDUSTRIAL
ENGINEER

DATA ANALYST
 2 . DUTIES AND RESPONSIBILITIES OF EACH
POSITION

DUTIES AND RESPONSIBILITIES

IE HEAD

 Analyzing the CM and Productivity details for all new development

styles based on garment sketch or samples and provide SAM to
merchandising department.
 After order confirmation, the evaluated garment is re-analyzed for
better and economical methods to reduce the negotiated CMT in
order to stay in safe margin..
 Releasing style PLAN FILE and thread consumption chart for line(s)
based on scheduled Line plan .
 Department wise Manpower requirement rationalization based on
target strength ratio.
 Co-ordination with planning department for allocation of similar
styles, capacity plan, line plan and factory monthly plan based on
the history of line and factory efficiency.
 Co-ordination with planning department for improving the pre-
production activities.
 Implementing all IE concepts and applying process improvements
cutting to packing.
 Initiative on lean manufacturing, learning of lean tools and looking
for scope of implementation.
 Draft and design layout of equipment’s, work flows , workspaces to
illustrate maximum efficiency using tools and equipment.
 Implement Lean Methodologies in the plant. Responsible for getting
A grades on all Lean KPI’s
 Review factory Non productivity Time reports and taking action plan.
  Implementing and following pre style change over activities to
reducing change over time.
 Co-ordination with HR manager for training progress (fresh training
and multi-skill training)
 Factory audit to be conducted to ensure the IED OB and Layout are
followed in line.
 Monitoring and Auditing IE and Jr.IE activities in all the units.

 Factory Production Incentive report monitoring and approval

 Working on new projects if any and suggesting advanced techniques
in garmenting 
 Monitoring & improving factory Efficiency and Cost per min value.

DUTIES AND RESPONSIBILITIES OF INDUSTRIAL ENGINEER

STYLE START UP

 Analyze the Sample with Technical dept and finalizing Operation

Breakdown
 Planning trail run for analyzing Critical operation and Sam
verification.
 Preparation of Plan file based on Operation Breakdown
 Preparation of Trims consumption.
 Preparation of Machine Layout & Issue to maintenance Dept.
 Plan & Follow up to arranging the Machineries and folders.
 Man Power Allocation based on OB
 Plan operator training for critical operations
 SWI (Standard Work instruction) and preparation of best Simulation
layout to achieve target efficiency with Operator utilization with TAKT
Time.
 Monitoring & Following on pre style change over activities.
 Preparation of Hourly production sheet and fixing the hourly target

DAILY ROUTINES
  Check Attendance
 Helping the Jr.IE in Line Balancing based on Capacity
 Discuss on daily Targets
 Monitoring Hourly Production & Conduct Bi Hourly Meeting with Jr.IE
 Guiding the Jr.IE to Solve the Bottle Neck and make sure the Line is
evenly Balanced
 Monitoring the Performance Report and taking action for reducing
Off Standard
 Monitoring the Low Efficient Operators
 Preparation of Yamazumi based on delivery quantity and makes the
operator utilization with proper efficiency
 Taking Responsibility Input to finishing
 Ensuring Proper Utilizations of Material
 To ensure that team should capturing Non productivity time input to
finishing.
 Maintain Line Discipline
 Time to Time Projects
 Analyze today's results and plan for tomorrow

WEEKLY ROUTINES

 Review Capacity Study and motivate Operator’s to achieve target

based on capacity
 Review the Method Study Documents with Jr.IE
 Review the Operator Learning Curve with Jr.IE
 Review Incentive Report and motivate all operators to achieve it
 Doing Pareto analysis & Why Why analysis for top 3 problems
 Review on Weekly Report Actual vs Target - Forecast Meeting
 PowerPoint Presentation - Weekly Review
MONTHLY ROUTINES

 Doing Monthly Style change over Plan

 Review the updation of Skill Matrix
 Details of Innovations Done
 Review on Actual Consumptions
 Identifying the Next Set of People to Work With
 PowerPoint Presentation - Monthly Review

DUTIES AND RESPONSIBILITIES OF JUNIOR IE’S (SEWING

FLOOR)

STYLE START UP

 Discuss on OB, Machineries and attachments

 Manpower Allocation should follow based on the skill allocation
sheet.
 Collect the Line Plan, Thread Consumption from Sr.IE
 Involve in pre change over activities & Line setting.
 Make sure the method and quality is set as per the standard with
Technicians
 Give the Individual target to the Operators

DAILY ROUTINES

 Arrive Early and Greet the arriving Employees

 Check Attendance
 Discuss on daily Targets
 Monitoring Hourly Production
 Solving the Bottle necks and the get the help of Sr.IE if required
  Capturing & Monitoring the Non productivity time from input to
finishing
 Bi Hourly Meetings with production team and highlighting the NPT .
 Monitoring the Operator Production Sheet and work on off standards
- Hourly
 Monitoring the Hourly WIP in each Operation
 Monitoring the Low Efficient Operators - Stamina Run
 Ensuring Proper Utilizations of Material
 Preparation of Daily Efficiency report
 Maintain Line Discipline
 Time to Time Projects
 Analyze today's results and plan for tomorrow
 Doing capacity study & Production study

WEEKLY ROUTINES

 Capacity Study
 Method Study
 Updating Operator Learning Curve
 Monitoring the Incentive Scheme
 Review on Weekly Actuals and plan for next week

MONTHLY ROUTINES

 Documentation of the Operators Improvement, the workings with the

specific Operator.
 Details Regarding Activities done to reduce Style Change over.
 Details of Innovations Done.
 Review on Actual Consumptions.
 Updating of Skill Matrix.
 Monthly Review Meeting with IE Manger & Sr.IE's.

DUTIES AND RESPONSIBILITIES OF DATA ENTRY OPERATOR

Data entry operator is also considered as a part of the IE
department. His activities include as following.

 Preparation of daily line and factory efficiency report

 Preparation of daily NPT reports with Pareto & Fish bone analysis.
 Preparation of daily line and factory lost time report
 Preparation of style costing report
 Preparation of MIS Meeting report
 Preparation of incentive working report.
3. INDUSTRIAL ENGINEERING FLOW CHART

IN DUSTRIAL EN GIN EERIN G FLOW CH ART

Reserach and
development Work Mesurement Garment & Plan Analysis MIS Reports Data Base development

Efficiency Reports
Estimated Costing SAM Time Study Plan File ( Cut to Pack ) Operator Skill Matrix

Perato & Fish bone

Trims Consumption Method Study Man & MC Requirement analysis KPI Mesurement

SAM calculation Production Target 5 why Analysis Machines Inventory

Cost per Minute

Line setting ( Target vs Actual ) SAM & Vedios Data bank

Method Improvment

Capacity study Production data

capturing

Bottleneck analysis

Line Balancing
5 PROCEDURE

 Providing estimated labor cost (CM) and productivity & SAM to

merchandising department for calculating the cost.
 Providing estimated trims consumption using the standard formulas
with adding the wastage % and send to merchandising department
for calculating the trims cost.
 Co-ordination with planning department for allocation of similar
styles, capacity plan, line plan and factory monthly plan based on
the history of line and factory efficiency Received monthly or weekly
Line Plan
 Analyzing and mapping the style process flow chart from cut to pack
before 10 days of style start.
 According to Line plan preparing the Plan File (OB & Layout) before
8 days of style start. (Sew & Finishing)
 Conduct the pre-style change meeting to discussing style plan file
& Get signature with Production & Quality team before 7 days of
style start.
 Preparing the Cutting operation bulletin before 8 days of style start.
 According to Style change Over SOP following the check list and
preplanning the Skill & machine.
 1st day of Line setting following the Line setting procedure
 Audit factory and lines to ensure the operation bulletin and line
layout are followed by line supervisor
 1 or 2nd day of style change check the operator capacity through
cycle time study
 2nd day of style change doing the bottle neck analysis using
Yamazumi graph.
 According to the required targeted output doing the line balancing
input to polybag.
 For bottle neck operation improving the Efficiency through
production or method study.
 2nd day of style change cross check and verifying the trims actual
consumption.
 Monitoring the hourly production and low efficiency operators.
 Capturing the Non-productivity Time for hour by hour.
 Preparing the Daily MIS reports and reports circulate to
management & team.
 According to NPT preparing the Pareto & Fishbone analysis.
 Preparing the OEE (Overall Effect and Effectiveness) Report.
 Daily arrange the management meeting for discussing factory
performances and Pareto & Fishbone analysis.
 According to Pareto analysis taking action plan for the problems.

 Creating the below data base development:

 Skill matrix
 Machine Inventory
 Video data bank.