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Showing posts with label Garment Manufacturing. Show all posts
Showing posts with label Garment Manufacturing. Show all posts

Thursday, August 28, 2014

How I Learned Industrial Engineering

How I Learned Industrial Engineering (and How You Can Too)?


For last 3 years I'm writing tutorials on Industrial Engineering topics ... and I learned many things on Industrial Engineering in this process. How did I learn that much of Industrial Engineering?

In this post I will share methods that I used to learn (and still using) Industrial Engineering and how you can too learn it. These are non-traditional learning methods but very effective. You can copy my techniques and learn Industrial Engineering.


Learning by doing: 

I don't have an Industrial Engineering degree. Whatever I know and learned about Industrial Engineering is by doing it myself. I read Industrial Engineering topics in college. I had seen many IEs to practice Industrial Engineering methods and to use IE tools in factories during my Internship and Graduation Project. When I was heading the Production Planning Department in an export house, I used to implement basic Industrial Engineering tools in the factory. I did many mistakes initially but I learned from my mistakes. 
So you can too learn Industrial Engineering by doing and practicing it on the floor. While doing something first time, you might make mistakes. That is the way to learn things. Keep it up. I learned production planning and merchandising also by doing it.

Learning by teaching others: 

I love to teach learners. Earlier I used teach my subordinates. When I was consultant I taught many participants from client companies. When I teach others I learn many things in the teaching process. You might read IE tutorials (articles) in OCS. Do you know how I learned all those topics? All because of OCS readers who force me to learn, so that I can teach them later and can write new tutorials. I get questions on various topics from OCS readers. I prepare the answers and when I prepare answer for a particular question, I need to research and read the topic first. Thus I learn it. 
To learn IE you can too start teaching your subordinates or juniors. You don't need to be master in your subject to teach others. Whatever you know more than others you can start teaching with that only. When you start teaching, you will be asked questions by your students. It is not necessary that you have to know all answers. If get chance you can learn the answer of the question and answer to your students. If don't find your student start teaching others from production department. 
If nobody asks you question, head over to OCS Forum and give answer to the questions that are posted there by other members. 

Learning by asking questions: 

This is the easiest way of learning something. When I meet with Industrial Engineers in export houses I ask different types of questions to them for clarification. I get answers for most of the questions, as they are working on this field for many years they know the answer. You can also start asking question to your seniors, when you need to know something. If you don't have senior or experienced colleague, you are welcome to send your questions to me or post your questions to the OCS Forum. 

Reading articles online and/or off line: 

I read articles on magazines or in the Internet daily. I learn many things by reading and also discover new areas of learning by reading. My reading topics are not limited to apparel production and Industrial engineering only. I read various topics to get ideas.

You can also start reading technical magazines related to Apparel Production Management and Industrial Engineering. If you don’t like to spend money on print magazines, read free articles on the Internet. By reading articles on Industrial Engineering you can increase your knowledge and you can teach others a new topic. 

Discussing topics with your colleagues and seniors: 

This is a great way of learning. Currently I don't have Industrial Engineering colleague. But I spent 2 and half years with a group of IEs. That time we had lot of discussion on Industrial Engineering. Still I practice this process of learning. As I said I regularly visit garment export houses. When I meet with factory IEs, we discuss things whatever we find interesting, within IE or out of IE topics. 

Watching videos on YouTube: 

YouTube is a great source for learning by watching videos. You will find numerous videos on sewing operations for different products, semi automatic and fully automatic sewing machines, and different types of material handling equipment. When you watch videos, observe it closely. You can learn many things like, good movements, workstation layout, working speed, machine types, attachment and guides used and many more things. 

Conclusion: 

There is no end of learning. And nobody can improve his/her performance continuously without learning. I have explained above how to learn Industrial Engineering. But these techniques are applicable to anything you like to learn.

Calculate Production Target and Worker’s Bonus on Initial Days of Production Start

How to Calculate Production Target and Worker’s Bonus on Initial Days of Production Start?


Question


Many of my orders are of 5,000- 22,000 pieces per style. My sewing line's output is around 1,200 pieces per day. So styles are finished within 1 -2 weeks and need to change style. In the first week of loading a style operators are not familiar with style and they learn in this period. So the time measurement is not correct to be a reference. Then in second week reference can be measured accurately but almost the styles get finished.

How can I set the target and bonus more adequate in this situation? Bonus amount should be attractive to workers and also fair to factory. Workers work on hourly wage.


Answer



The problem raised in this question is a fact of garment manufacturing factories. When a new style is loaded to a line, operators learn on initials day and produce less. That is one of the reasons for low production compared to pick production or average daily production. 

In this article I will explain how you can set production target and operator bonus effectively even on the initial days of the production start.

Setting Production Target


You might already know the formula that is used to calculate daily production target of a style. If don’t know here it is.

Production Target per day = (Number of operators X Working hours per day X 60 X Line Efficiency%)/ (Product SAM)

There are two problems in using this formula calculating production target on the learning stage.
  1. You wouldn't know actual line efficiency – as efficiency will build up day by day up to pick efficiency level. And without past data you can’t assess what would be the efficiency of day 1, day 2 or day 3.
  2. Product SAM - assuming that you are not using Predetermined Motion Time System (PMTS) for measuring product SAM. Production capacity is estimated based on time study of the production line. This has been indicated in the question.
The only solution of this problem is that you have to develop database for line efficiency at the learning stage. This period is called as learning curve. Develop learning curve of your lines (style wise, order wise) by studying styles. Measure the trend - how production build up happen and reach to pick production day by day at the learning stage. Once you have enough data on efficiency build up (learning curve) you can make target plan for the future orders. Learning curve may vary depending on order quantity and style difficulty level.

Learning curve (Efficiency% Vs Days) of a typical garment factory for one style is shown in the following Fig. In this learning curve day wise efficiency build up is shown.
Figure: Learning Curve

Similarly develop database for standard time for your styles by using Time Study method.

Now you have both data to calculate production target even at the learning stage. Practice it and write me if find any issue in using the above method.

How to Set Worker Bonus?


You can set workers performance bonus at the learning stage for individual worker or/and for the group without much difficulty. It is the similar method that you use calculating bonus amount on the normal production days. The difference is - in this period the target efficiency% for becoming eligible for earning bonus to be kept lower than normal production. Design day wise target efficiency based on your learning curve. You can keep the bonus amount per point increment of efficiency same. Or slightly more to motivate your operators working harder.

Tools and Equipment used by Industrial Engineers


Tools and Equipment used by Industrial Engineers in the Garment Industry


In their day to day job, Industrial Engineers (IE) use various type of tools and equipment. What all equipment and tools to use, depend on the job responsibilities of an IE in a company. Name of the common tools and equipment are listed below. Purposes of the tools are also mentioned here.

Stop Watch (Digital or analog): Measuring observed time at the time of Time Study.

Measuring Tape: Measuring length of seams and measuring distances


Picture (Clock wise direction): Digital Camera, Digital Stop
Watch, Digital Tachometer, Measuring tape

Digital Camera: Capturing videos for various operations that help in motion analysis of operations.

Tripod for the camera: Used as camera stand.

Time Study board: Required during time study to hold the Time Study format.

Calculator: Data calculation and report making.

Tachometer: to measure speed of the motor of sewing machine. This equipment is use to find machine rpm.

Data capturing and process analysis formats: For example- Time Study format, Motion analysis format etc. Data capturing and analysis to bring improvement.

Various documents: Documents are used to assist production and other processes with information, methodology or layout. Formats are like Operation Bulletin, Line Layout, Pitch Diagram, Hourly report format etc.

Computer: Data analysis, Report making, Mailing, video analysis of operations etc.

Standard Hours Earned in Garment Manufacturing

What is Standard Hours Earned in Garment Manufacturing?


Standard Hours Earned term is not much known in garment factories. Here, Work Study officers or Industrial Engineers working in garment manufacturing factories (Export house or domestic garment manufacturing) don't use 'Standard Hours Earned' instead engineers use Standard Minutes produced or Standard Minutes earned. So when we heard this term first time, we think it might be a different measure.

Let me explain what does ‘Standard Hours Earned’ mean.

This is similar to Standard Minute Produced by workers. Instead of minutes it is presented in hours. To get Standard hours earned value, standard minutes are divided by 60. Like, if an operator works for 8 hours a day and produce garment equivalent to 360 minutes then operator’s standard hours earned would be 6 hours (This is derived from: 360 minutes/60).


Formula for calculating standard hours earned:


Standard hours Earned = (SAM of operation X Garments produced)/60

This term is also called as Earned Hours because operator has earned that many hours by his/her effort.


Benefit of using Standard Earned Hours

- Easy to compare produced hours against available hours in a day (efficiency)

- Secondly calculating earning amount (in Dollar) of an operator from earning hours is easy as you know standard hourly rate of your operators.



Also See: How to Calculate Standard Hours Earned, Operator Efficiency and Labour Cost?