Some Essential Formula and Example for Industrial Engineer (IE)

Industrial engineering is a branch of engineering which is used to eliminate waste of time, money, materials, machine time, energy, person-hours, and other resources that do not generate value. As like other manufacturing industry, industrial engineering now widely used in textile and apparel industry. Textile and garment industry have to face heavy challenges due to various factors including global competition, production costs increase, less productivity/efficiency, labor attrition, etc. For overcoming those challenges industrial engineering knowledge and formulas are frequently used in apparel manufacturing industry. In this article I have given some important and popular terms and formulas of industrial engineering. I have also given some examples for which reader can easily understand.

Some Important Formula & Example for IE

   1. Standard Pitch Time (S.P.T) = Basic Pitch Time (B.P.T) + Allowances (%)
         
  • GSD = (Man power * Work hour) / Target          
  • SMV = Basic time + (Basic time * Allowance)          
  • Basic time = Observed time * Rating
  • Observed time = Total Cycle time / No of cycle
  • Rating = (Observed Rating * Standard rating) / Standard rating
  • Efficiency = (Earn minute * Available minute) * 100
  • Earn minute = No of Pc’s (Production) * Garments SMV
  • Available minute = Work hour * Manpower
  • Organization Efficiency = (Basic pis time / Bottle neck time) * 100
  • Basic pis time = Total GMT SMV / Total Manpower
  • UCL = Basic pis time / Organization Efficiency
  • LCL = 2 * Basic pis time – UCL
  • Capacity = 60 / Capacity time in minute
  • Cycle Time = 60 / Team target
  • Capacity Achievable = Capacity * Balance
  • Daily output = Work hour / SMV
  • Factory capacity = (Work hour / SMV) * Total worker * Working day * Efficiency
  • CPM = (Total over head cost of the month / No of SMV earners * Work minutes) *Efficiency
  • Required no of operator = Target daily output / Daily output per operator

Example:

1. Efficiency = Output/Input

                      = (SMV*Product Quantity) / (Worker*Working Hour*60)

                      = [(38.50*700) / (60*10*60)]*100

                      = 74% (Line Efficiency)

Here,
SMV=38.50
Working hour=10
No. of worker=60

2. Target/hour = (60/SMV)*Efficiency%

                        = (60/0.85)*70%

                        = 50 pcs/hour

Here,
SMV=0.85
Efficiency=70%

3. Target/line = [(No of worker*working hour*60)/SMV]*Efficiency%

                       = [(75*10*60)/23.5]*60%

                       = 1150 pcs

Here,
No of workers=75
Working hours=10
SMV=23.5
Efficiency=60%

4. Required days for the schedule = Total order quantity/Average target

                                                         = 50000/2000

                                                         =25

Here,
Average target=2000
Order quantity=50000

5. CM of garments= (Total Production)/(no of worker*work hour)

                               = 250000/(1500*10)

                               =1.66 BDT

Here,
Total Production=250000
No of workers= 1500

6. Factory capacity = [(Work hour*total workers*working day*60)/SMV]*Efficiency

                                = [(10*1500*26*60)/14.13]*55%

                                = 828025 pcs/month


7. Line GSD/day = (Manpower*work hour)/target

                             = (50*10*60)/900

                             = 33

You can also like:
  1. A Comprehensive Study on Lean Manufacturing Process
  2. An Overview of Work Study in Textile Industry
  3. Concept of New Product Development
  4. Factors Influencing Productivity in Textile Industry
  5. Line Balancing in Apparel Production
  6. Primary/Basic Elements of Lean Manufacturing Process
  7. Product Life Cycle | Stages and Limitations of Product Life Cycle (PLC)
  8. Risks of Higher Productivity in Garment Industry
  9. Roles of Industrial Engineer in Apparel Industry
  10. Some Essential Formula and Example for Industrial Engineer (IE)
  11. Stages of the New Product Development (NPD) Process
  12. Techniques of Work Measurement and Their Applications
  13. The Strategies View of Industrial Engineering and Its Discussion
  14. Tools and Techniques of Industrial Engineering Used in Apparel Industry
  15. Work Measurement in Textile Industry
  16. Working Flow Chart of Method Study
 
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Editor-in-Chief:

Mazharul Islam Kiron is a textile consultant and researcher on online business promotion. He is working with one European textile machinery company as a country agent. He is also a contributor of Wikipedia.


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