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Industrial Engineering in Apparel Manufacturing

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 INDUSTRIAL ENGINEERING
IN APPAREL MANUFACTURING
Dr. Prabir Jana and Dr. Manoj Tiwari

“A P rac t it ioners Gu id e ”

Foreword i
 Contents
Evolution and Trends 1
Key Performance Measures 16
Apparel Manufacturing Systems 35
Method Study 44
Operator Rating 58
Work Measurement 76
Allowances 103
Work Sampling 116
Operation Bulletin 130
Resource Planning 143
Material Handling 157
Incentive Schemes 169
Workplace Safety and Ergonomics 184
Plant Layout 211
Value Engineering 232
Recruitment and Training 245
Industrial Engineering and Lean Manufacturing 267
Setting up of an IE Department 284
Index 303

vi
Industrial Engineering in Apparel Manufacturing
Foreword
Since the beginning of civilization, human beings by their nature, have been
involved in continuous improvements and have had an unending thirst to
raise living standards and improve the quality of life every day! Industrial
Engineering has played a vital role in achieving these objectives. Apparel
Manufacturing has improved significantly from Industrial Engineering
techniques, although not as much as in other industries, especially
automobile manufacturing.
Industrial Engineering (IE) became a significant factor during the
Industrial Revolution in Europe during the mid-eighteenth century, and
one of the first industries to apply its principles was the textile industry. The
pressure of producing more with less resources resulted in many inventions
for mass production. Such inventions and techniques dramatically changed
manufacturing practices and served as fertile ground for other scientific
concepts and principles. Eventually this led to the formal acknowledgment
of the field known today as Industrial Engineering.
Henry Ford’s Model T, produced on an assembly line, and Taylor’s
Principles of Scientific Management were notable concepts that changed
the dynamics of mass manufacturing of that era. And they are still
totally relevant. World Wars I and II played a major role in providing a
nurturing environment to Industrial Engineering principles. This also led
to the development of some newer fields such as Operations Research,
Mathematical Modelling, Applied Statistics, and Automated Simulation
Techniques. In the last 150 years, the roles and scope of IE have changed
drastically. In recent times, it has transformed into a multi-disciplinary
field with a combination of Technology and Management, and of
course, Engineering.
As far as apparel manufacturing is concerned, it is a known fact that it is
both labour-intensive and skill-oriented. Industrial Engineers need to focus
on Work Measurement, Cost Control, Quality Control, Line Balancing,
and Operator Training in addition to implementing more Robotics and
Automation as well as Lean Manufacturing Systems. Sewing factories have

Foreword iii
 historically implemented fewer technological and process advancements
compared to other manufacturing areas. This is especially true for less
developed areas like Asia and Africa although significant amounts of textile
and apparel products are produced in these regions. These conditions
collectively present a difficult challenge to channel the ideas and achieve
world-class productivity and quality.
In apparel manufacturing, IE techniques have not been given enough
attention in Asian countries, even though they are needed to survive in
this highly competitive business environment. This has resulted in more
IE theory and fewer practical applications. One of the primary reasons for
this is the shortage of quality literature discussing the practical applications
of theoretical principles in the apparel manufacturing environment.
I appreciate and respect the efforts of the authors to offer such a highly
relevant book titled “Industrial Engineering in Apparel Manufacturing- A
practitioner’s guide”. This book has successfully provided a much-needed
platform where practitioners can see what can be done using IE techniques
and how they should be done. In addition, this book can also help them
evaluate what has happened to this point. The inclusion of Industry Practices
in each chapter makes this book even more useful and relevant, and shows
how the authors have tried to bridge the gap between theory and practice.
This book can definitely help practitioners implement Industrial
Engineering tools in a more effective and efficient manner. I believe it
will be a true guide and add significant value to IE practitioners from the
apparel industry as well as from academia.

Dr. Michael T. Fralix, President and CEO, Textile Clothing Technology

Corporation, USA

iv
Industrial Engineering in Apparel Manufacturing
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