Introduce yourself:

I am Md Ashiful Alam. I am from comilla. Recently, I have completed my graduation from

Ahsanullah University of Science & Technology in the program of Industrial & Production

Engineering.

Besides this I also completed a 72 credit hours professional degree on SCM from ISCEA

Bangladesh. I have two journal papers in IJSER.ORG about Inventory cost Optimization.

I was the campus Ambassador of PTAKPrize 2017 and volunteer of Enliven Bngladesh

I organized a seminar on global supply chain management in my campus and participated

SCM competition on EW Agro Supply Chain club.

I did an industrial attachment in Midas Safety and visited more the 10 industries.

What’s your strength?

I m a good learner and good team leader for example I was the team leader in my product

design project and thesis work group.

I have a good communication skill.

When I want to do something and I try my best to complete the task with my full

concentration.

What’s your weakness?

I like to make sure that my work is perfect, so I tend to perhaps spend a little too much

time checking it but it will be beneficial after a long time ago.

I feel frustration when I have been working so hard for something but nothing happen.

Eng. Md. ASHIFUL ALAM, CSCA tm

B.Sc. in Industrial & Production Engineering
Ahsanullah University of Science & Technology
 Interview Question about Supply Chain Management

 What is supply chain Management?

Ans:

SUPPLY CHAIN MANAGEMENT (SCM) is the management of the flow of goods and services which
involves the movement and storage of raw materials, of work-in-process inventory and of finished goods
from point of origin to point of consumption.

It’s a transformation of natural resources and raw materials into finish goods that delivered to the end
customer.

 Sources of Supply Chain revenue: Customer

 Sources of Supply Chain cost: flow of information, products & found between stages of supply chain

 What is Lead Time?

Ans:
Time required to purchase, produce and assemble an items
 What is Competitive Strategy?

Ans:

The plan to utilize the products or services of an organization to satisfy the demand or needs of customers.

 Competitive strategy drives supply chain strategy

 What is level & chase strategy?
Ans:

Chase strategy: production rate is synchronized with demand by varying machine capacity or hiring and
laying off workers as the demand rate varies

Level strategy: maintain stable machine capacity and workforce levels with a constant output rate

 Supply Chain Efficiency vs. Responsiveness

Ans:
Responsiveness and Efficiency are polar opposites.
Efficiency saves money and increases profits throughout your business but responsive supply chain has to
be responsive to your needs and it has to be responsive to the needs of your customers.
Supply chain efficiency requires speed and large, uniform orders. Responsive demands high service level,
variety of products and variety of quantity, short lead time.

Eng. Md. ASHIFUL ALAM, CSCA tm

B.Sc. in Industrial & Production Engineering
Ahsanullah University of Science & Technology
 How many Drives in Supply Chain, which are they?
Ans:
Six drives and they are Facilities, Inventory, Transportation, Information, Sourcing & Pricing.

 1st three are Logistics drives and 2nd three are cross functional drives.
 Biggest drive in supply chain: Information

 What are Facilities, Inventory, Transportation, Information, Sourcing and Pricing?

Ans:

Facilities:

Place where inventory is stored, assembled or fabricated.

It could be production site and storage sites.

 Increasing the number of facilities increases facility and inventory costs but decreases transportation
costs and reduces response time.
 But increasing the flexibility of a facility increases facility costs but decreases inventory costs and
response time.

Inventory:

Raw materials, Work in Process (WIP), finished goods

Pressures for high inventories-Customer Service, Ordering Cost/Setup Cost, Labor and

Equipment Utilization, Transportation Costs, Quantity Discount

Pressures for low inventories- Cost of Capital, Storage and Handling, Taxes, Insurance,

and Shrinkage

Cycle inventory-average amount of inventory used to satisfy demand between shipments

Safety inventory-inventory held in case actual demand exceeds forecasts, or in case

supply shortfalls occur

In-transit inventory-En-route goods or materials which are in the ownership of the firm

but in the possession of the carrier.

Total Cost-cost of material+ holding costs+ ordering and/or set-up costs

Eng. Md. ASHIFUL ALAM, CSCA tm

B.Sc. in Industrial & Production Engineering
Ahsanullah University of Science & Technology
 Holding cost-the sum of the cost of capital and the variable costs of keeping items on

hand, i.e., storage and handling, taxes, insurance, and shrinkage

Ordering /set-up cost-purchase order preparation cost or production order preparation,

i.e., costs involved in preparing a machine to produce an item.

Transportation:

Moving inventory from point to point in a supply chain and it’s combination of

transportation modes and routes.

 Carrier--party that moves or transports the product

Information:

Data and analysis regarding inventory, transportation, facilities throughout supply chain.

Sourcing:

The set of business processes required to purchase goods and services.

Pricing:

The process by which a firm decides how much to charge for its products or services.

 What is MPS & MRP?

Ans:

MPS (Master Production Schedule)-statement in terms of specific products of what is to

be produced and when

MRP (Material Requirements Planning)-computerized information system developed

specifically to help manufacturers manage dependent demand inventory and

schedule replenishment orders

 BOM (Bill of Material): list of components, ingredients, and materials needed to make

product.

Eng. Md. ASHIFUL ALAM, CSCA tm

B.Sc. in Industrial & Production Engineering
Ahsanullah University of Science & Technology
Enterprise resource planning (ERP):
ERP provides an integrated and continuously updated view of core business

processes using common databases maintained by a database management

system. ERP systems track business resources—cash, raw materials, production

capacity—and the status of business commitments: orders, purchase orders, and

payroll. The applications that make up the system share data across various

departments (manufacturing, purchasing, sales, accounting, etc.) that provide the

data.[1] ERP facilitates information flow between all business functions and manages

connections to outside stakeholders

Names of ERP based software:

SAP, SYSPRO, ODOO, INFOR, MICROSOFT DYNAMICS

What is Lean Supply Chain?

Lean supply chain management is about reducing costs and lowering waste as much

as possible. This methodology is important for organizations with high volumes of

purchase orders since waste and costs can accumulate quickly.

Additionally, companies with high volumes of low variability purchase orders, such as

food items, benefit their efficiency greatly by utilizing the lean supply chain

methodology.

What is Agile Supply Chain?

Agile Supply Chain is built to be highly flexible for the purpose of being able to
quickly adapt to changing situations. This methodology is considered important for

organizations that want to be able to adapt to unanticipated external economic

changes, such as economic swings, changes in technology, or changes to customer

demand.

Implementing an agile supply chain allows organizations to quickly adjust their

sourcing, logistics, and sales.

Eng. Md. ASHIFUL ALAM, CSCA tm

B.Sc. in Industrial & Production Engineering
Ahsanullah University of Science & Technology
 Importance terms of SCM
 ABC Analysis: used to establish inventory management policies that focus on the few critical

parts and not the many trivial ones.

 Backlog: all customer orders that have not shipped. Includes past due, current, and future
orders
 Backorder-a past due order for an item with insufficient inventory or some other problem

 Bullwhip effect: fluctuations in an order increase as they move up the supply chain

 Cross-docking:-materials are moved directly from receiving to shipping and are not placed in
storage in the warehouse.

 CRP (Continuous replenishment program)-inventory management practice in which the

wholesaler or manufacturer replenishes a retailer, based on POS data at the retailer, or
warehouse withdrawals

 CSL (Cycle service level)-desire probability of not running out of stock in any ordering cycle.

 DMAIC (Define-Measure-Analyze-Improve-Control):-Six sigma

 Structured approach EDI (Electronic Data Interchange)-computer to computer exchange of
routine business documents such as invoices, purchase orders, payments, order status, etc.,
 Economic Order Quantity -lot size that minimizes total annual inventory holding and
ordering/set-up costs

 Fishbone diagram (aka Cause-and-effect diagram)- simple graphical method for presenting a
chain of causes and effects and for sorting out causes and organizing relationships between

variables
 Forecasting- the art and science of making projections about what future demand and
conditions will be,

 Make-or-buy-decision regarding the manufacture or purchase of item or service.

 Push/Pull- Push production is based on forecast demand. Pull production is based on

actual or consumer demand.

Eng. Md. ASHIFUL ALAM, CSCA tm

B.Sc. in Industrial & Production Engineering
Ahsanullah University of Science & Technology
 Important Question about Industrial Engineering
What is Lean management?
Ans:

Lean is a systematic method for waste (muda) minimization within a manufacturing

system without sacrificing productivity in order to increase efficiency and quality.

Lean also takes into account waste created through overburden (muri) and

unevenness (mura).

What is Kaizen =kai(change)+zen(good)?

Ans:

Improving the quality of work in an organization by achieving TQC (Total Quality

Control).

5W & 1H of Kaizen:

1. WHO 2.WHAT 3.WHERE 4.WHEN 5.WHY

1. HOW

Kaizen 5S:
1. Sort: Removing unnecessary items from the workplace.

2. Set-in-order: Keep needed items in the correct place.

3. Shine: Clean the workplace and equipment.

4. Standardize: Keep to the rules in order to maintain.

5. Sustain: Revisit in sort, set-in-order and shine on frequent basis and confirm

the condition

Kanban:
A way of waste reduction where established an upper limit of work in progress

inventory for avoiding overloading.

Value Steam Mapping (VSM):

A planning tool to optimize result by eliminating waste.

Eng. Md. ASHIFUL ALAM, CSCA tm

B.Sc. in Industrial & Production Engineering
Ahsanullah University of Science & Technology
Six sigma:
Improving quality of final product declining cases of defect

DMAIC (Define-Measure-Analyze-Improve-Control)

7 Wastes: (TIMWOOD)
1. Transportation
2. Inventory

3. Unnecessary movement

4. Waiting in a queue
5. over production

6. Over processing
7. Defects

Poka-yoke (Mistake proofing):

Eliminating product defect by preventive, corrective and human error
Efficiency vs. Effectiveness:
Efficiency: Performing the best possible manner with the least waste of time

Effectiveness: Effectiveness is the level of result from the action

Just-in-Time:
In manufacturing, reducing flow times within production system as well as response

times from suppliers and to customers.

SAM OR SMV:
(Standard Allowable Minutes or Standard Minutes Value)

Eng. Md. ASHIFUL ALAM, CSCA tm

B.Sc. in Industrial & Production Engineering
Ahsanullah University of Science & Technology
Responsibilities of IE:
Though the time study and motion study are the most common function of Industrial
engineer, the some other responsibilities are

Planning layouts
Monitoring Production flow system
Decide the machines and attachments for all style

Pay system
Monitoring and improve the operator performance

Operator training

Production control system

Quality control

Others

Basics Techniques of Industrial Engineering:

There are some basic terms, which are important to know before learning IE. Short
descriptions of these terms are highlighted below:

Capacity Study:
It is exactly the measure of the operator same as capability. It means the operator is capable
of achieving the performance measured by the study. The major Need for capacity study is
to set Quotas, to motivate operator, and to measure the productions section capacity. By

measuring the individual operator capacities, supervisor can determine the overall capacity

of their section. It is simply the sum of individual capacity.

Procedure:
Use of stop watch
Measure the time study

Average the time cycle

Eng. Md. ASHIFUL ALAM, CSCA tm

B.Sc. in Industrial & Production Engineering
Ahsanullah University of Science & Technology
This average cycle time measures the operator ability to do the particular job. It’s the

measure of the skill of particular operator. Because the Industrial Engineers want to measure
the skills and ability of the operator in their average cycle time.

Benefits of Capacity Study:

Check targets

Motivate operators
Measure section production capability

Method Study:
Method study is the systematic recording and critical examination of existing and proposed
ways of doing work, as a means of developing and applying easier and more effective
methods and reducing costs.

The procedures which need to do follow while doing method study are given as follows.
There are seven steps to be followed by industrial engineers to do method study they are,

 Select the work to be studied

 Define the objective
 Record the relevant information and data
 Examine information and data
 Develop the improved method

 Install improved method

 Maintain the improved method

 Work measurement

Time Study:
Work measurement is carried out by time study. Time study is a work measurement
technique for recording the times and rates of working for elements of a specified job carried

out under specified conditions and for analyzing the data so as to obtain the time necessary
for carrying out the job at a level of performance. The concept of Rating is fundamental of
time study. Rating is the process used by industrial engineer to compare the actual

Eng. Md. ASHIFUL ALAM, CSCA tm

B.Sc. in Industrial & Production Engineering
Ahsanullah University of Science & Technology
performance of the operator with operator mental concept of normal performance. The rating

is the numerical values used to denote the ratio of working. In order to rate the operator
ether must be a defined level of performance to compare with, an average level. For this the

industrial engineers apply the concept of a “Standard operator”. A standard operator is a fully
trained and motivated to perform a defined task and is, by definition average in terms of his
/her work place.

The steps to do the time study is as follows,

Observe the job and analyses to determine the element

Rate each element to compare with the accepted standard

Use the stopwatch to time each element
Average the selected element times
Multiply average element time by rating
Add the basic time for all the element
Add allowances

Here the elements are the small components into which an operation is divided for study
purpose. They are selected for the convenience of the observation, measurement and
analysis. These elements should be clear and fully describable during the data presentation

and analysis that.

Operator Performance:
Basically the operator performance can be monitored with the help of three efficiency
factors.

Single cycle efficiency

On-standard efficiency

Global efficiency

Eng. Md. ASHIFUL ALAM, CSCA tm

B.Sc. in Industrial & Production Engineering
Ahsanullah University of Science & Technology
Single cycle efficiency = [Target single cycle time in minutes (SC@100%)] / [Average

observed single cycle time in minutes (SC average)]

Here we are considering the cycle time only.

On-standard efficiency = [Operator production × SAM per piece for the operation] / [Working
time in minutes − Off-standard time in minutes]

Here the unproductive time is not considered.

Off-standard Time:
The time spent by an operator at his work under a condition that is not considered as

productive. Types of off-standard

Machine break down (m/c failure, thread cuts, needle breakage, etc.)

Waiting time (No WIP , Waiting for the bundle)

Quality problems
No feeding
Un familiar job (Working other than her regular operation)
Training

Global efficiency = [Operator production × SAM per piece for the operation] / [Working time
in minutes]

Here, the total working time is considered (even unproductive time is also considered).

Follow-ups:
This requires that someone checks on and stays with something until desired results are

achieved. Any project being implemented successfully may fail if the follow-up is not

consistent. Here we are going to concentrate on operator performance follow up.

Eng. Md. ASHIFUL ALAM, CSCA tm

B.Sc. in Industrial & Production Engineering
Ahsanullah University of Science & Technology
Benefits of Operator Follow-ups:

Improve performance (motivate)

Prove job quotas

Spot troubles

Types of follow-ups

Bundle by bundle follow-up

Bundle diagnosis

Bundle by Bundle Follow-up:

This follow-up is done when the operator’s on-standard efficiency is much less than his
single cycle efficiency in that operation.

Single cycle (SC) efficiency is arrived considering the cycle time taken by the operator to
complete each piece. Whereas the on-standard efficiency is arrived considering the pieces
produced during the productive time spent in that operation for a definite period of working
time.

So, if the on-standard efficiency is much less than her single cycle efficiency, it means the

operator is unable to maintain the pace in all the pieces when she is working for a long time.
During this condition, the bundle by bundle follow-up will help in finding/solving the problems

that occur between each bundle.

Bundle Diagnosis:
This is done when the operator’s single cycle efficiency of the operation is less.

Process of Bundle Diagnosis:

To do a bundle diagnosis, a stop watch and the format is required.

Write down the descriptive data required (IE, operator, operation, instructor, etc.).

Eng. Md. ASHIFUL ALAM, CSCA tm

B.Sc. in Industrial & Production Engineering
Ahsanullah University of Science & Technology
Determine the SAMs for the number of units in the bundle.

Measure the time for each activity of the operator and write it in the appropriate category in
the format.

After finishing the bundle, calculate the bundle efficiency, the single cycle efficiency and
compare against the SAMs.

Key Points for Bundle Diagnosis:

Do not interfere in the operator’s work

Be alert and prevent any interruptions

Write down everything

Analyze the information and obtain your conclusions

It is equally important that the conclusions obtained turn into specific actions that can be

taken to improve the operator’s performance. Perform bundle diagnosis and give your

comments clearly.

Work in Process (WIP):

The semi-finished or finished goods which transported from one work station to next work
station are called work in progress.

WIP is made up of all garments and their parts that are not completely finished.

It can be measured in units (pieces) or time (minutes).

For example – if an operator a takes 0.8 minute per piece to stitch and if she has 3 bundles

of 10 pieces each to be processed, then the WIP in that workstation is 30 pieces or 24

minutes.

Need to Control WIP:

Two major cost areas can be reduced if WIP is controlled.

Eng. Md. ASHIFUL ALAM, CSCA tm

B.Sc. in Industrial & Production Engineering
Ahsanullah University of Science & Technology
1. Investment in inventory is the money invested in raw materials. If the inventory is not

moved through the plant quickly then it affects cash flow directly.

2. Ability to reduce the production cycle

By having low inventory between operations, garments usually have less waiting time and go
through the production cycle in less time. Large inventory levels between the operations

keep the goods waiting longer to be processed. This increases the overall through put time.
Low through put time permits better co-ordination between sales and production.

Low cycle times give manufacturers the ability to handle multiple styles.

Clients/buyers are looking for the factories that can meet production schedules, that can
handle multiple styles, and that can handle low inventories which will reduce their
investment.
The factories that work with low WIP only will be able to sustain in the present market.

How to Manage WIP?

The WIP can be managed by following the activities given below strictly.

1. Production planning
This requires planning from marketing and sales to determine the type, period and quantity
of products to be produced in the factory.

Efficient per-production team (sampling, R&D and merchandising) should play a key role in

order selection and preparatory activities before starting the style.

2. Trims control

Trims are buttons, zippers, labels, thread, elastics, and so on.

All the trims should be in house before commencing the bulk production.

An updated trims inventory report should be kept. The unavailability of even a small label
could stop the production.

3. Production build-up

Eng. Md. ASHIFUL ALAM, CSCA tm

B.Sc. in Industrial & Production Engineering
Ahsanullah University of Science & Technology
Loading should be done based on the date-wise production build up plan, prepared by

considering the capacity of the sewing line. If the loading greatly exceeds the quantity that
the line is able to process, it will end up in huge WIP, thus affecting the complete flow.

4. Balancing
Even if the line is loaded based on the capacity, there is a chance of increased WIP in the
line due to unbalanced production.

This may happen due to absenteeism, labor turnover, change in style, bad cutting, etc.
Based on the inventory level data in each work station, the line can be balanced using utility

operators, through required operator transfers and over time.

5. Cut flow control

To control WIP, the cycle times are to be kept low by following FIFO procedure for every cut.
This can be ensured by utilizing cut tracking sheet and bundle tracking sheet.

Why Industrial Engineering is Need in Apparel Industry?

Industrial way of garment production needs a thorough preparation of production because in

the same time, it is necessary to combine a few factors: people, time, machines and place of
production, organization and material in a coordinated and rational system. Technological
system of garment production must enable expected quality of product, necessary scope of

production, delivery of ready-made garments in the expected time, maximum use of capacity

with minimum expenses. An Industrial Engineer can perform several activities to fulfill their
task, Processes and Procedures of manufacturing or service activities can be examined

through Process Analysis. Industrial engineers can use Work Study comprehending Method

Study and Time Study. The mentioned activities are also called operations Management.
Furthermore can Industrial Engineering involve inventory management to make a
manufacturing process more feasible and efficient. Industrial Engineers used to increase

efficiencies and cost-effectiveness of operations by the products strategies like High-volume

production, long-runs and minimal variations.

Eng. Md. ASHIFUL ALAM, CSCA tm

B.Sc. in Industrial & Production Engineering
Ahsanullah University of Science & Technology