INDUSTRIAL ENGINEERING IN GARMENT PRODUCTION

III B.TECH FASHION TECHNOLOGY

UNIT I

Dr.D.Raja, Professor/FT
M R Karthikeyan, Assistant Professor/FT
 Industrial Engineering is an Engineering knowledge is
applied to the planning, design, and control of
industrial operations by integrating peoples, materials
and energy in productive ways.
Objectives of Industrial Engineering
Monitoring production floor and having better control
over the production floor
Improving processes and method of working to
increase factory's overall performance and
standardized garment manufacturing processes
Contribute to the success of companies through
effective problem solving
2
TECHNIQUES OF WORK STUDY

Work Study
Work
Method Study Measurement
(Better Way to do Job)
(Time takes to do Job)

Higher
Productivity 3
COURSE OUTCOMES
At the end of the study of this course the students will be
able to,
1. Explain the importance of productivity and discuss the
role of industrial engineer in the garment industry.
2. Discuss the various procedure and techniques involved
in method study.
3. Explain the objectives and procedure to measure work
content in the garment industry and also discuss its
importance.
4. Explain the importance of plant layout, standardization
techniques and analyze the lean manufacturing
technology in the garment industry.
5. Discuss the various planning, control tools and material
4
handling systems used in garment industries.
 PRODUCTION

 The action of making or manufacturing from components or raw

materials, or the process of being so manufactured.

 Production is the process of combining various inputs, both

material (such as textile, garments, accessories metal, wood,
glass, or plastics) and immaterial (such as plans, or knowledge)
in order to create output/product.

 Production is any progress or procedure developed to transform a

set of input elements like men, machinery, capital, information
and energy into a set of output elements like finished products
and services in proper quality and quantity, thus achieving the
objectives of an enterprise.

5
PRODUCTION SYSTEM
A production system is the set of
interconnected input–output elements and
is made up of three components, namely
inputs, processes and outputs.

6
 PRODUCTIVE SYSTEMS
 The productive system is defined as the means by which we
transform resource inputs to create useful goods and service as
outputs.
 The nature of the process for manufacturing is the first factor
which influences the layout.
 Continuous process industry - A continuous process industry
may be defined as one where the process is continuous all the
time day and night,, and it is impossible to stop production
process at a short notice. Ex: Rayon Production.
 Repetitive process industry - the product is processed in mass.
of industry varieties of operations may be involved in different
departments. Ex: telephones, televisions.
 Intermittent process industry - On intermittent industry is one
that processes items as and when orders are procured. It is
some time called a job-lot industry. Ex: Embroidery. 7
TYPES OF PRODUCTION

 Job-Shop Production: A production process, in

which few products are created according to the
demand of the customer, in the stipulated time and
cost. In job-shop production, product volume is low,
and variety is high.
 Batch Production: Batch production is one wherein
product passes through various stages over a series of
functional departments, and a number of batches are
produced.
 Mass Production: It is a manufacturing technique in
which discrete parts are produced with the help of
continuous process.
 Continuous Production: The process of production
in which the production facilities are sequenced as per
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the production operations chronologically.
PRODUCTIVITY
 Productivity of a production system is analogous to the efficiency
of a machine.
 Productivity may be defined as the ratio between output of
wealth and input of resources of production.
 Output means the quantity produced and inputs are the various
resources employed, e.g., land, building, machinery, materials
and labor.
𝑂𝑢𝑡𝑝𝑢𝑡
Productivity =
𝐼𝑛𝑝𝑢𝑡
 Productivity refers to the efficiency of the production system.
It is an indicator of how well the factors of production (land,
capital, labor and energy) are utilized.
 It may also be defined as human effort to produce more and
more with less and less inputs of resources as a result of which
the benefits of production may be distributed more equally 9
among maximum number of people.
DYNAMIC CONCEPT OF PRODUCTIVITY

10
 PRODUCTION AND PRODUCTIVITY

Basis for
Production Productivity
Comparison
Meaning Production is a function of Productivity is a measure of
an organization which is how efficiently resources
associated with the are combined and utilized
conversion of range of in the firm, for achieving
inputs into desired output. the desired outcome.
What is it? Process Measure
Represents Numbers of units actually Ratio of output to input
produced.

Expression Absolute terms Relative terms

Determines Value of output Efficiency of factors of
production

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 Production is defined as the process or procedure to transform a
set of input into output having the desired utility and quality.
 Production is a value addition process. Production system is an
organized process of conversion of raw materials into useful
finished products.
 Production refers to absolute output where as productivity is a
relative term where in the output is always expressed in term of
inputs.
 Increase in production may or may not be an indicator of increase in
productivity.
 If the production is increased for the same input, then there is an
increase in productivity.
𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛
Productivity = 12
𝑅𝑒𝑠𝑜𝑢𝑟𝑐𝑒𝑠
Productivity is said to be increased, when
 1. the production increases without increase in inputs.

 2. the production remains same with decrease in inputs.

 3. the output increases more as compared to input

A company produces 160 kg of single jersey fabrics by consuming
200 kg of yarn for a particular period.
For the next period, the output is doubled (320 kg) by consuming
420 kg of yarn and for the third period, the output is increased to
400 kg by consuming 430 kg of yarn. Comment based on
productivity.

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KEY DIFFERENCES BETWEEN PRODUCTION AND PRODUCTIVITY
 Production is an organized activity, wherein step by step conversion of
raw materials into useful output takes place. On the contrary,
Productivity is an indicator of efficiency in the production in terms of
optimum utilization of firm’s resources in the creation of desired
output.
 Production is a process of value addition, wherein at each level, some
value is added to the product. Conversely, productivity is a measure of
efficiency.
 Production exhibits the number of units produced by the firm in a
given period. As against, productivity highlights the ratio of output to
input consumed.
 Production is always expressed in absolute terms, i.e. the volume of
output produced. On the other hand, productivity is denoted in relative
terms, meaning that it determines the quantitative relationship
between output generated and resources consumed.
 While production ascertains the value of output generated,
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productivity determines the how well the resources are utilized by the
firm in the generation of output.
 BENEFITS FROM INCREASED PRODUCTIVITY
 Higher productivity results in higher volume of production and
hence increased sales, lower cost and higher profit

(a) Benefits to the management:

1. More profit.
2. Higher productivity ensures stability of the organization.
3. Higher productivity and higher volume of sales provide opportunity
for expansion of the concern and wide spread market.
4. It provides overall prosperity and reputation of the organization.

(b) Benefits to workers:

1. Higher wages.
2. More wages permits better standard of living of workers.
3. Better working conditions.
4. Job security and satisfaction 15
 BENEFITS FROM INCREASED PRODUCTIVITY…
 Higher productivity results in higher volume of production and hence
increased sales, lower cost and higher profit

(c) Benefits to the consumers:

1. More productivity ensures better quality of product.
2. It also enables reduction in prices.
3. More satisfaction to consumers.

(d) Benefits to nation:

1. It provides greater national wealth.
2. It increases per capita income.
3. It helps expansion of international market with the help of
4. and good quality products.
5. It improves standard of living.
6. It helps better utilization of resources of the nation
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FACTORS AFFECTING PRODUCTIVITY
Factors affecting national productivity
 Human resources
 Technology and capital investment
 Government regulation
Factors affecting productivity in manufacturing and services
 Product or system design
 Machinery and equipment
 The skill and effectiveness of the worker
 Production volume
Human resources
 The general level of education
 Use of computers and other sophisticated equipment by
employees
 Employees need to be motivated to be productive
 Technology and capital investment
 New technology depends on R & D
 Every industry and services put new technology into use, they
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must invest in new machinery and equipment
 Computer aided design (CAD)
FACTORS AFFECTING PRODUCTIVITY
Government regulation
 An excessive amount of government regulation may have a
detrimental effect on productivity.
Product or system design
 R&G is a vital contributor to improved product design.
 Standardization of the product and the use of ‘group technology’
are other design factors that make possible greater productivity in
the factory.
 Value analysis’ can bring out many product design changes that
improve productivity.
Machinery and equipment
 Once the product is designed/redesigned, then how it is made
offers the next opportunity for productivity improvement..
 CNC machines & Computer aided manufacturing (CAM)
 Skill and effectiveness of the workers:
 The trained and experienced worker can do the same job in a
much shorter time and with far greater effectiveness than a new
one and Even the well-trained employees must be motivated to be18
productive as well.
 FACTORS AFFECTING PRODUCTIVITY
Production volume
Assume that the volume of output is to be doubled, the number of
direct workers would have to be doubled and a few indirect workers
might also be needed. But there would probably not be a need for
more engineers, research scientists, head quarters staff persons or
other support personnel. So if the output is doubled, the productivity
of these support people is in effect doubled.

Economic growth
The economic growth of a country depends on the national
productivity. The national productivity will automatically increase if
productivity of individual industrial and productive unit increases,
we shall consider the factors that affect the productivity of an
individual unit. They are as follows:

 Land and building

 Material
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 Machinery and equipment
 Men (Labor)
 PRODUCTIVITY MEASURES
Labor productivity
The resource inputs are aggregated in terms of labor hours.
Hence this index is relatively free of changes caused by wage
rates and labor mix. By improving methods of work
(eliminating unnecessary movement, etc.) the output of a
worker can be increased

The productivity of labor can be increased by increasing efficiency of

labor, reducing idle time.
For example, let us take a turner who was producing 20 pieces an hour
and the same turner, by the improved methods of doing work is able to
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produce 25 pieces an hour. Then productivity has increased by
[(25 - 20)/20] × 100 = 25%.
PRODUCTIVITY MEASURES….
Machine productivity
By use of sophisticated modern machines, better method of
manufacture and reducing idle time of machines, the number
of pieces (items) produced by a machine per hour can be
increased.

For example, let us assume a machine was producing only

100 pieces per working day of 8 hours.
The machine tool has fitted with a better tool that permitted
more depth of cut and higher cutting speed.
As a result the output from the machine increased to 130
pieces in a day of 8 hours. In this case, the
productivity has increased by [(130 - 100)/100] × 100 = 30% 21
 PRODUCTIVITY MEASURES….
Material productivity
Materials that can be converted into products to be sold, both as
raw materials or auxiliary materials such as solvents or other
chemicals and paints needed in the process of manufacturing and
packaging material.
By product design and by use of skilled workmen, material
wastage can be greatly reduced. Thus from a given quantity of
material more number of pieces can be produced.

For example, a worker may cut 10 metal discs from a given length
of metal plate per hour. A skilled worker by improving the method
can cut 12 pieces in one hour.
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Then in this case, the productivity of material has increased by
[(12 - 10)/10] × 100 = 20%.
 PRODUCTIVITY MEASURES….
Capital productivity
Several formulations are possible for this measure. In one, the
resource inputs may change during the period of depreciation, in
another, the input may be the book value of capital investment.
Energy productivity
The resource input is the amount of energy consumed in kilowatts.
Land productivity
On industrial side, the productivity of land and buildings is said to
have increased if the output of goods and services within that area
is increased.
Overall productivity
It is the ratio of total output to the sum of all input factors. Thus a
total productivity reflects the joint impact of all the inputs in
producing the output

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 LINE EFFICIENCY
Sewing Line Efficiency
 In the garments industry, efficiency is the ratio of produced
minutes to spent minutes multiplied by 100.
The common formula to calculate efficiency is-

Here,
 Output = Number of garments pieces produced in the line

 SMV = Standard Minute Value of the garment

 Manpower =Number or the worker worked (Operator + Helpers

 Working minute = Total minute work to produce the garments.

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 LINE EFFICIENCY ……
Example:
 A sewing line output is 1600 pcs in 9 hours. The operator was 32,
the helper was 4 and the ironman was 2 and the garment SMV is
7.32. What is the efficiency of the sewing line?
Here,
 Output = 1600 pcs
 SMV = 7.32
 Manpower = 32+4+2 = 38
 Working minute = 9 hours = 9 × 60 = 540 minutes

 If we put all the value in the efficiency formula we will find the
efficiency of that sewing line.

Sewing Line Efficiency = [(1600 × 7.32)/(38 × 540)]×100 = 57.08%

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For more example, refer to the following table. Data calculation
formula has been given on the header row of the table.

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INDUSTRIAL ENGINEERING

Industrial Engineering is an Engineering knowledge is

applied to the planning, design, and control of
industrial operations by integrating peoples, materials
and energy in productive ways.
Objectives of Industrial Engineering
 Monitoring production floor and having better control
over the production floor
 Improving processes and method of working to
increase factory's overall performance and
standardized garment manufacturing processes
 Contribute to the success of companies through
effective problem solving 29
TECHNIQUES OF WORK STUDY

Work Study
Work
Method Study Measurement
(Better Way to do Job)
(Time takes to do Job)

Higher
Productivity 30
ROLE OF INDUSTRIAL ENGINEERS
 To effectively & efficiently utilizing the
• software technologies
• Machine tools
• Mathematical and Scientific concepts
• Managing the human resources
• Demand of customer satisfaction
• Time schedule
 Evaluation of existing production target and fix a
new production target.
 Constant control of direct labor cost.

31
ROLE OF INDUSTRIAL ENGINEERS…..
 Data analysis and look into monthly trends
 Preparing daily production reports, Monthly
improvements reports with graphical presentation.
 Time study and updating time study database
including videos on constant basis.
 Research on motion study and implementation of
the better system to eliminate excess motions.
 Research on new machinery and latest systems that
meets companies long term goal and preparing cost
benefits analysis
 Research and development for samples prior to
production start.
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ROLE OF INDUSTRIAL ENGINEERS IN
APPAREL INDUSTRY

 Collect line loading plan from Planning Dept .

 Attend in PP meeting
 Collect Size set sample & make Operation Bulletin
 Collect Operation Bulletin & make paper layout
 Discuss with Maintenance in-charge regarding
machine, folder, attachment & Technical personnel
for technical issues
 Make discussion with floor in -charge about layout
according to paper layout
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 Check Daily Non- productive time (NPT) and reduce
ROLE OF INDUSTRIAL ENGINEERS IN APPAREL
INDUSTRY

 Make layout according to paper layout

 Make line balancing according to target & capacity
study during 2 -3 days of layout
 Find out bottleneck process & solve
 I f needed make 1hour production study in required
process
 Everyday input and output monitoring
 Give daily production target and follow up production
achievement .
 Hourly production follow -up 34
ROLE OF INDUSTRIAL ENGINEERS IN APPAREL
INDUSTRY
 Cross check thread consumption for every new style
 Ensure 65 -70% efficiency .
 Work station design
 Operators motion development by correcting faulty motion .
 Reduce worker absenteeism and turnover rate
 5 pcs flow by reducing W IP
 Reduce line setting time or throughput time
 Proper utilization of manpower by reducing unnecessary helping
process .
 Establish a meeting in- between QC & operators regarding
critical points of the style while layout .
 Prepare daily Man/ Machine report 26 . Developing cut to ship
ratio.
 Work to reduce absenteeism and operator turnover 35
OBJECTIVES OF INDUSTRIAL ENGINEERING (IE)
IN THE APPAREL INDUSTRY

 To increase productivity
 Process improvement by motion reduction.
 Reduce work in process (WIP) and remove the
bottleneck.
 Increase the efficiency of operations
 Reduce man-machine ratio
 Process improvement to reduce cost, waste and
rejection Reduce wastage and defects
 Fill up Key Performance Indicator (KPI) target.
 Keep workplace and environment safe 36
OBJECTIVES OF INDUSTRIAL ENGINEERING (IE)
IN THE APPAREL INDUSTRY….

 Production planning and implementation

 Evaluate operator and staff performance, disciplinary
matters, training needs, and career development.
 Set the target and make a draft, layout design of the
machine requirement, material flow, and workstation
to bring the best possible efficiency. Modern tools are
used to design the layout.
 Monitor factory performance in terms of quality,
delivery, cost-efficiency, and target improvements
with the internal factory team and taking necessary
corrective action.
 Manpower balancing, target setting, and
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monitoring achievements.
BASIC TECHNIQUES USED IN INDUSTRIAL
ENGINEERING
 Work study: A system of assessing methods of working to
achieve the maximum output and efficiency.
 Capacity Study (Production and M/c)
 Method Study: is basically recording & critical examination of
existing and proposed ways of doing work
 Time Study: Time study is a direct and continuous observation
of a task, using a timekeeping device
 Operator Performance: SMV (Standard Minute Value)/
SAM(Standard Allowed Minute)
 SMV is defined as the time which is allowed to perform a job
satisfactorily. Normally it is expressed in minute value.
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 IE IN ERGONOMICS
 Ergonomics (Greek: Ergon = work + Nomos = custom, law) is
an interdisciplinary scientific approach to problems of
adjusting work to humans, aiming to increase productivity,
i.e. working efficiency, work safety, and humanization of
human labor.
 Ergonomics is a multi- and interdisciplinary science that
deals with human–machine system in order to adjust the
machine to human’s bio-psycho-social limitations and
requirements, to use the machine more efficiently, safely, and
reliably.
 Ergonomics is a scientific discipline that examines the
relationship between a human and his material environment,
in order to optimally subordinate it to humans.
 Ergonomics is the study of human abilities and
characteristics that affect the design of equipment, systems
and jobs, and its aims are to improve efficiency, safety, and 39

well-being.
Ergonomics has following areas
 Designing organization of a
working system
 Organization of the flow of process
 Designing workplace
 Designing working areas
 Designing working environment
 Selecting and training employees

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 IMPORTANCE OF ERGONOMICS
Industries increasingly require higher production rates
and advances in technology to remain competitive and stay
in business.
As a result, jobs today can involve:
 Frequent lifting, carrying, and pushing or pulling loads
without help from other workers or devices.
 Increasing specialization that requires the worker to
perform only one function or movement for a long period
of time or day after day.
 Working more than 8 hours a day.
 Working at a quicker pace of work, such as faster
assembly line speeds; and
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 Having tighter grips when using tools.
BENEFITS OF A WORKPLACE ERGONOMICS PROCESS

 Ergonomics reduces costs.

 Ergonomics improves productivity.
 Ergonomics improves quality.
 Ergonomics improves employee engagement.
 Ergonomics creates a better safety culture.

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POSES IN GARMENT PRODUCTION
 Apparel manufacturing is a labour-intensive assembly line
process requiring significant amounts of repetitive and
skilled manipulations.
 Therefore, like any other manufacturing industry, it has its
own share of ergonomic problems where poorly designed
and unorganized workstations contribute to
musculoskeletal discomfort among the sewing operators.

43
44
Awkward postures
This can make tasks more physically demanding by increasing the exertion
required from smaller muscle groups, and preventing the stronger, larger
muscle groups from working at maximum efficiencies.
Handling or assembling very small parts and materials or performing
extremely precise tasks may contribute to eye strain and awkward postures.
Forceful efforts
Force is the amount of muscular effort expended to perform work. Exerting
large amounts of force can result in fatigue and physical damage to the body.
Pressure points result from the body pressing against hard or sharp surfaces.
Vibrations
Tools that are not properly maintained or are inappropriate for the task may
increase the amount of hand-arm vibration and result in fatigue, pain,
numbness, and tingling, increased sensitivity to cold and decreased sensitivity
to touch in the fingers, hands, and arms
Repetitive motions
Repetitive work involves duplication of certain motions over and over again
resulting in awkward postures and forceful exertions of the same muscles,
45
tendons or joints. This subsequently increases the risk of injury and results in
wastage of time leading to delays in production.
ERGONOMIC PRINCIPLES IN
MANUFACTURING ENVIRONMENT (RMG)

Ergonomic principles in the designing environment

are as follows:
 Microclimate

 Light

 Noise

 Vibration

 Color

 Music and

 Hygienic conditions

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Microclimate
 A man in a work process can be exposed to adverse
climatic and microclimatic conditions of the working
environment.
 The term microclimate includes conditions in a small area,
usually around the workplace, and all the factors these
conditions vary upon humidity, temperature, air
movement.

Measures to protect health and safety related to the

microclimate at work are as follows: heat radiation, etc.
 Mechanization and automation of production processes
 Normalization of conditions with the help of air
conditioners that maintains the desired normal
temperature, humidity, and velocity of air
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 Ventilation and heating
Light
 Keeping in mind the fact that eyesight is very important in all
work activities, lighting is an important factor in the work
environment and a necessary condition for performing work
processes.

 Inadequate lighting has a negative impact not only on eyesight

but also on the psychological state of a worker, the productivity at
work, and occupational injuries.

 The condition under which it is best to place a work process is in

daylight, and if it is not always possible to achieve it, artificial
lighting must be used.

48
Proper lighting of workspace should have..
 Protect eyesight

 Reduce fatigue of eyesight and nerve-muscle tension

 Provide high accuracy at work and reduce the number of

errors
 Increase productivity in all activities and

 Reduce the risk of injuries

To ensure favorable light, adequate attention should be

paid to:
 1. Strength

 2. Consistency and

 3. Uniformity of light
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Noise
 Noise is any unwanted sound that disrupts, disturbs
and damages psychophysiological functions of the
organs of the human body. The unit for measuring
the intensity of noise is decibel (dB).

Noise in the workplace

 The noise generated by a device (machine) on which
the employee works directly
 The noise generated by other devices (machines)
 The noise from the so-called non-production sources
(e.g. apparatus for ventilation and air conditioning)
and sounds from the environment (e.g. traffic) 50
Measures to reduce the impact of noise.
 Use of machines and tools that make little noise

 Proper arrangement of machines.

 Regular maintenance and repair of machinery.
 Rotation of workplaces.
 Maximum possible removal of the workers from the source
of noise.
 Physical fencing of workplaces from the source of noise.
 Sound insulation of floors, ceilings, walls, wall partitions
and windows.
 Using curtains in front of the windows .
 Using personal hearing protection devices (like ear plugs
51
and earmuffs).
Vibration
 Vibrations are oscillations at low frequencies that
usually occur with infrasound and spread through
direct contact.
 Vibrations that are examined from the standpoint of
safety and health at work are called humane vibration
and are examined at places where touchable working
tools the worker is in contact with vibrate and are
tested in the range of 1–100 Hz.
 Short-term exposure to vibration can cause back pain,
headaches, nausea, fatigue, insomnia and slow
reactions.
 Prolonged exposure produces serious damage to the
spine 52
 Security measures of occupational health
protection from vibrations

 Extraction of the machine or device that produces

noise and vibration.
 Constructional changes with the application of plastic
materials.
 Installation of plastic shims under the machines and
devices that produce vibrations.
 Installation of partition walls or covering the walls
with materials that do not block sound waves, etc.
 The usage of personal protective equipment for safety
and health at work.
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 COLOR AND MUSIC
 Color surrounds us and affects us every day. Color
affects people psychologically, physiologically and
economically.
 Color can encourage thinking; it can move people and
cause different reactions.
 It can irritate or soothe, raise blood pressure or reduce
the appetite.
 It is estimated that up to 60% of the acceptance or
rejection of a product or service is associated with
color.
 People use colors to communicate and to influence
their moods and feelings.
54
Colors in the work environment contribute to easier and
faster orientation, proper lighting, space harmony, safety at
work, optimization of the visual nerve-function of the
operator, feeling of comfort, concentration, general
improvement of the working environment, and work
satisfaction.

55
Music
 Music is often used in rooms where work is performed in
order to. eliminate the negative effects caused by noise.
 Music at work, if properly applied, can be an important
tool to increase productivity, depending on the work
rhythm and the noise in the plant or in the office.
 Music affects physiological processes (e.g. heart rate),
mobility activities, moods, emotions and cognitive
processes (memory).
 According to many studies, music at work eliminates the
fatigue of workers, reduces monotony, increases the
willingness to work, contributes to the better mood of
workers, reduces anxiety, etc.
 The optimal duration of music is 25% of the total
working time (about 2–2.5 hours during shifts) and
at intervals of 12–20 minutes. 56
TEMPERATURE AND VENTILATION STANDARDS

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