INDUSTRIAL ENGINEERING – UNIT II

Main objectives
• Main objectives of Industrial
Engineering is to find:
–The best way to do a work
–The time required to do it
–The way to measure results
 Role of Industrial Engineer
1. Plant Layout
2. Operation breakdown
3. Work study
4. Determine (Decide) the target and Operator
performance analysis
5. Line balancing (Machines and adjustments)
6. Capacity study
7. Maintaining skill matrix
8. Operator Training (Cross training operators)
9. Production flow and control system
10. Quality control
11. Plant safety
12. Maintenance
 Causes for Low productivity
• Improper layout
– It increases material transportation time
– Main purpose of choosing a better layout is to reduce
transportation time in the line.

• Improper workstation layout

– A scientific layout is defined as minimum reach for picking up and
dispose of components
– Every components and tools(trimmer) must be kept within
operator reach.

• Line setting time (or) style changing

– The time lost in the initial days (learning curve) brings down the
average labour productivity
• Improper line balancing
• Lack of work aids and attachments
– These are some kinds of time saving devices that
facilitate operator to perform the work effectively
with less effort
• Irregular feeding of material
– Poor production plan, ineffective cutting department
• Off standard time
– Non productive time such as waiting for work,
machine breakdown, power failure and repair work
kill your productivity
 INDUSTRIAL ENGINEERING TECHNIQUES IN
APPAREL INDUSTRY
 One major technique of Industrial Engineering
followed in the Apparel Industry is the WORK STUDY.
 Work Study investigates the work done in the
most effective way of using the resources and with the
minimum time as possible.
 The phases of Work Study which are also the
techniques of Industrial Engineering used in the Apparel
Industry are
1) METHOD STUDY
2) WORK MEASUREMENT
3) TIME STUDY
 Workstudy
• - which involves least
possible time and
causes least possible
fatigue to the worker
METHOD STUDY

Method study is the systematic

recording and critical examination
of ways of doing things in order to
make improvements.
Developing and applying easier and
more effective methods and
reducing costs.
PURPOSE OF METHOD STUDY
 
 To determine the optimum working
method.
 To standardize the work.
 To train the workers.
 To manage the work
 Objectives
1. To eliminate wastage of time and labour
2. To reduce fatigue and boredom of work by
avoiding unnecessary movements
3. To find the best way of doing a job
4. To have more effective utilization of materials,
machines and work force.
5. To improve the design of workplace layout
6. To standardize the method, obtained after
conducting the motion study.
7. To train the individual worker in its practice as per
standardized method.
 BASIC PROCEDURE OF METHOD STUDY:
 
  1) SELECT
2) RECORD
3) EXAMINE
4) DEVELOP
5) MEASURE
6) DEFINE
7) INSTALL
8) MAINTAIN
 PROCEDURE OF METHOD STUDY:
•SELECT - Selection of the job or process to be studied.
•RECORD - Recording from direct observation everything
that happens using the most suitable methods like process
charts, diagrams, models, motion and film analysis, etc.
•EXAMINE - Examination of the recorded facts critically.
•DEVELOP - Development of the most economic method.
(Elimination, Combining, Rearrangement, Simplification)
•MEASURE - Measurement of the quantity of work and
calculate the standard time.
•DEFINE - Definition of the new method and the related
time.
•INSTALL - Installation of the new method as the new
standard practice.
•MAINTAIN - Maintenance of the new standard practice by
proper control procedures.
 LEVELS OF ANALYSIS OF METHOD STUDY
 
1)   WORK PROCESS LEVEL – Eg: Sew the
front tuck.

2)    WORK COMPONENT LEVEL – Eg: Take the

garment body, fold the tuck, allign the needle
entry point, and reverse stitch.

3)  MOTION COMPONENT LEVEL – Eg:

Extend the hand to the garment, grasp the
garment body, bring the garment body to the
table, and place the garment body on the table.
 Selection of work
Factors considering when selecting job

1. Economic or cost effective

considerations
– Operation which produced large amount of scraps or
waste
– Bottleneck operations which are holding up other
production operations

2. Technical considerations
– Need automation and advanced technology

3. Human considerations
– Fatigue or monotony or may be unsafe or clumsy to
operate
• Ergonomics (Human
Engineering): It is concerned with
study of relationship between
man and his working conditions
to minimize mental and physical
stress. It is concerned with man-
machine system
 Method Study

• Old Method • New Method

• SCT - 51 seconds • SCT - 34 seconds
(0.85 minutes) (0.57 minutes)
• Capacity/ day - 565 • Capacity/ day – 842
• % of improvement- 49 %
• Old Method • New Method
• SCT - 59 seconds • SCT - 54 seconds
1.Picking VA vs NVA 1. Pick
2.Place on table
2. Place on table
3.Pick fused material
3. Pick fused material
4.Match
4. Match
5.Place under pressure foot
5. Place under pressure
6.Backtack foot
7.Pick collar bone 6. Backtack
8.Match collar bone 7. Pick collar bone
9.Sewing 8. Match collar bone
10.Turning 9. Sewing
11.Aligning 10. Turning
12.Sewing 11. Aligning
13.Aligning 12. Sewing
14.Sewing 13. Pick collar bone
15. Aligning 21. Sewing
14. Match
16. Sewing 22. Turning 15. Sewing
17. Aligning 23. Aligning 16. Turning
18. sewing 24. Sewing 17. Sewing
19. Pick collar bone 25. Backtack 18. Backtack
26. Inspection 19. dispose
20. Match collar bone
27. dispose
• The analysts goal is to eliminate as
much as the non-value-added
elements as possible by
reengineering the design of the
product or process.
• The objective of value analysis is
maximizing the utility provided by the
product or service and minimizing or
eliminating waste.
Effective tool for method study

Flow process chart

• This is a graphical
representation of operation,
transportation, inspection,
delays and storage occurring
during production.
 FLOW PROCESS CHART
A flow process chart is a graphic symbolic
representation of the work performed or
to be performed on a product as it passes
through some or all of the stages of a
process.
Typically, the information included in the
charts is quantity, distance moved, type
of work done by symbol with
explanation, and equipment used. Work
times may also be included.
Process chart symbols
 Types of Charts
• Product analysis
• Man analysis
• Equipment analysis
 USES of flow process chart
• Elimination or simplification of operations.
• Elimination or simplification of inspections
needed or relocation of inspection points.
• Reduced in movement distance of man or
materials in shops.
• Reduction in delay or waiting times.
• Reduction in number or elimination of periods
of temporary storage of materials between
operations. This saves floor space as well as
reduces the work-in-process at any given time.
 Flow diagram
• Flow diagram is a drawing or a
diagram which is drawn to scale.
• It shows relative position of
product machinery, jigs, fixtures
etc and marks the paths followed
by men and materials.
 Steps
• Draw to scale the plan of the work area.
• Mark the relative positioned of machine tools,
benches, stores, racks, inspection booths etc.
• From the different observations, draw the
actual path of the material or the worker on
the diagram and indicate the direction of
movement. Different movements can be
marked in different colours.
• Process symbols may also be added on the
diagram.
 Flow Process and Flow Diagram
They are very useful in
establishing the overall
sequence of operations and in
determining the best layout for
an economic and effective
flow of materials
 Benefits
• These charts will improve methods
of production, sequence of operation
and layout etc. Thus, work can be
reduced, time can be saved and
expenses can be cut.
 Multiple Activity Chart
• This chart describes graphically the
activity of a man and machine he is
attending against a time scale.
• Where a number of workers work in a
group or an individual operator handles
two or more machine, their activities
have to be coordinated for achieving
proper results.
 Multiple Activity Chart
• A man-machine chart (multiple
activity chart) records
simultaneously the activities
of all the workers and
machines on a common time
scale and thus shows inter relations
between them
 Objective
• (i) To detect idle times being enforced on machines
and workers
• (ii)To optimize work distribution between workers
and machines.
• (iii) To detect number of workers in a group
• (iv) Ultimately, to develop an improved method of
accomplishing a task and to have an effective
labour cost control.
Multiple Activity Chart
 Analysis
• Now, therefore, the problem is which
alternatives would be economical?
For this purpose, the unit cost of idle
time of one worker and the unit cost
of idle time of each machine is
estimated and then the economical
alternative is calculated
 Travel Chart
• The chart which gives an estimate
about the amount of material
handling between various work
stations is known as travel chart.
The amount of travel depends upon the frequency of
movements between sections of departments

A travel chart helps improving the existing plant

layout.
 Travel Chart
Existing plant layout showing the locations of various departments (A to F)

A travel chart is advantageous because it brings

out the relative importance of having different
parts of departments close to each other.
 Step : 3
A square grid is drawn and the
• Step : 2 various movements are marked
• Movements A to B are
20; B to A =10; B to C =
15; A to F = 25, C to D =
30; D to C = 50; D to F =
40; E to F = 10; F to E =
15

data regarding the origin and

destination of the movement of
any worker (or material or
equipment) during a given
period.
 Step 3 is simplified by combining
movements like A to B (20) and
B to A (10) which involve some distance
and therefore total movements = 30

• B‹=›A = 20 + 10 = 30.
The simplified travel
chart shows
movements as :-
• A‹=›B = 30 B‹=›C = 15
• C‹=›D = 80 A‹=›F = 25
• D‹=›F = 40 E‹=›F = 25
 According to these figures, maximum number of movements is between
department C and D, hence in the plant layout there two departments should be
side by side. The next lesser number of movements is between D&F, hence D and
F should also lie closer to each other and so on.

The modified layout with the help of Travel Chart

80

25
40 30
25

Old layout
Uses of Travel Chart
 To analyse material handling and plan department
locations.
 To compare layouts and to determine their efficiency.
 To plan materials handling procedure and routes.
 To shorten manufacturing cycles.
 To reduce work in progress.
 To reduce labour costs.
 To assist improving materials handling procedure.
 To determine relative self-sufficiency of various areas.
 To determine inventory control difficulties.
 To make economical use of available areas.
 String Diagram
• When the paths are many and
repetitive, a flow diagram
becomes congested and it is
neither easy to trace it nor to
understand.
• Under such conditions a string
diagram is preferred.
 String Diagram
• It is a special type of flow diagram,
generally prepared when the
movements involved (of men,
material or equipment) are large and
cannot be comprehensively
recorded by flow diagram
String Diagram
 Construction
1. Identify the process
2. Produce scale map of work area
3. Add all machine furniture to the diagram
4. Add flow process symbols
5. Connect and tie the process
6. Start and finish points
7. Rearrange the movable items on the map
1. Mobility
2. Function
3. Product
8. Repeat step 4 to 6
9. Check step 7 for feasibility
• Uses:-
• (i) It is very useful in dealing with complex
movements and plant layout and design
problem.
• (ii) Indicates clearly, back tracking, congestion
bottlenecks and over and under used paths on
the shop floor.
• (iii) Measures the distances involved and points
out whether a work station is suitably located.
• (iv) Traces modifications in existing path
 Principles of motion economy
• Rules concerning human body
• Rules concerning workplace layout
and material handling
• Rules concerning tools and
equipment design
• Rules concerning time conservation
• Principles of Motion Economy
1. The movements of the two hands should be balanced
and the two hands should begin and end their motions
simultaneously.
2. The hands should be doing productive work and should
not be idle at the same time except during rest periods.
3. Motions of the hands should be made in opposite and
symmetrical direction and at the same time.
4. The work should be arranged to permit it to be
performed with an easy and natural rhythm.
5. Momentum and ballistic-type movements should be employed
wherever possible in order to reduce muscular effort.
6. There should be a definite location for all tools and materials, and
they should be located in front of and close to the worker.
7. Bins or other devices should be used to deliver the materials
close to the point of use.
8. The workplace should be designed to ensure adequate
illumination, proper workplace height, and provision for alternate
standing and sitting by the operator.
9. Wherever possible, jigs, fixtures, or other mechanical devices
should be used to relieve the hands of unnecessary work.
10. Tools should be prepositioned wherever possible in order to
facilitate grasping them.
11. Object should be handled, and information recorded. Only once
Design of workplace area
• 1. Actual Working Area.
It is most convenient
area for working.
• 2. Normal Working
Area. It is within the
easy reach of the
operator.
• 3. Maximum Working
Area. It is accessible
with full arm stretch.
Classification of movements
WORK MEASUREMENT
 
Work Measurement is the application of techniques
designed to establish the time for a qualified worker
to carry out a specified job at a defined level of
performance.
BASIC PROCEDURE FOR WORK MEASUREMENT:
1) SELECT
2) RECORD
3) EXAMINE
4) MEASURE
5) COMPILE
6) DEFINE
PROCEDURE OF WORK MEASUREMENT
 SELECT - Selection of the work to be studied.
 RECORD - Recording the relevant data relating to the
circumstances in which the work is being done and also the
methods and elements of activity in them.
 EXAMNIE - Examination of the recorded data and the
detailed breakdown critically to ensure that the most effective
method and motions are being used.
 MEASURE - Measurement of the quantity of the work
involved in each element in terms of time.
 COMPILE - Compilation of the standard time for
operation.
 DEFINE - Definition of the series of activities and method
of operation for which the time has been compiled.
APPLICATIONS OF WORK MEASUREMENT:
 
 Work measurement is used to find the
existing causes of ineffective time.
 It is used for the setting of sound time
standards.
 To provide information on which estimates for
tenders, selling prices and delivery commitments
can be based.
 To set standards for the machine utilization
and labour performance.
 To provide information for the production
planning and scheduling.
COMPARISON BETWEEN METHOD
STUDY AND WORK MEASUREMENT:
 
 Method study and Work measurement
are closely related.
 Method study is concerned with the
reduction of work content of a job or
operation.
 Work measurement is concerned with
the investigation and reduction of any
ineffective time associated with it.
TIME STUDY
 
 Time Study is the art of observing and recording the
time required to do each detailed element of an
industrial operation.

 A Time Study consists of the following:-

1)     Dividing a certain item into minute work
components.
2)     Recording the time required to finish the work
using the appropriate time measuring device.
3)     Specifying the standard time and making work
improvements based on the results obtained
PROCEDURE OF TIME STUDY:
 
1) Obtain and record all the information available about
the job, the operative and surrounding conditions.
2) Record a complete description of the method,
breaking down the operation into elements.
3) Examine the detailed break down to ensure the most
effective method and motions are being used and
determine the sample size.
4)  Measure with a stop watch and record the time taken
by the operative to perform each element of operation.
5)  At the same time, assess effective speed of
working of the operative, relative to the
observer’s concept of the rate corresponding to
standard rating.
6)  Extend observed times to basic times.
7) Determine the allowances to be made over
and above the basic time for operation.
8)  Determine the standard time for operation.
Standard of living
 Observed Rating,
Timing the basic steps (pick-up-process- Operator performance Approximately
Dispose-pick-up) by using stopwatch. rate (Efficiency level at 30% of BT
the time of Timing)
 One Mark QP
• Method study is the systematic recording and
critical examination of ways of doing things
in order to make improvements.

• Objectives of method study (any 3)

To find the best way of doing a job
To eliminate wastage of time
To standardize the method
BASIC PROCEDURE OF METHOD STUDY: (First 4)
1) SELECT
2) RECORD
3) EXAMINE
4) DEVELOP
BASIC PROCEDURE OF METHOD STUDY: (Last 4)

5) MEASURE
6) DEFINE
7) INSTALL
8) MAINTAIN

Factors considering when selecting job

1. Economic or cost effective
considerations
2. Technical considerations
3. Human considerations
 • relationship between man and his working
conditions to minimize mental and physical
stress. Ergonomics (Human Engineering)
The primary objective of method study is ______
a) Select a method (b) Examine a method (c) Develop a method
(d)Record a method

Find the VA element from the given below

a) Dispose (b) Inspection while sewing (c) unwanted
alignment (d) None of these
• The Method study analysts goal is to
eliminate as much as the non-value-added elements
as possible by reengineering the design of the product
or process.
A method can be improved by
a) Using skilled operator (b) Reduce idle time (c)
Increase efficiency (d) Reduce NVA element
Find the NVA element from the given below
a) Sewing (b) Picking (c) Manual trimming while sewing
(d) Dispose
 Multiple activity chart deals with the relationship
1._____
between operator and machine
 Objective of multiple activity chart
• (i) To detect idle times being enforced on machines
and workers
• (ii)To optimize work distribution between workers
and machines.
• (iii) Ultimately, to develop an improved method of
accomplishing a task and to have an effective
labour cost control.
• Define method study
• List the benefits of method study
• Factors considering to selecting job for method study
• Explain the step by step procedure to carry out
method study
• What is VA and NVA
• State about principle of motion economy
• Explain in detail about principle of motion economy
• What is ergonomics
• List the benefits of ergonomics with respect to
productivity