Industrial Engineering Formulas for Textile Students and Professionals

Industrial Engineering Formulas for Textile Students and Professionals
Joyankar Mojumder
Executive-IE, Paddocks Jeans Ltd.
DEPZ, Savar, Dhaka.
Mob: 01813171408
Email: mozumderjoy@yahoo.com


Industrial Engineering:
Industrial engineering is a branch of engineering which studies the design and operation of production and service systems and the people who operate in these systems. Industrial engineering helps to improve quality and productivity. It is said that without industrial engineering operations is like meal without salt and if you use operation management instead of production management it will be best.

We can see at a glance of IE,

Industrial Engineering (IE) = Production ↑ Cost ↓ Proper use of all elements ↑ Efficiency ↑ Profit ↑

Some Important Formula for Industrial Engineering:
Some important formula of industrial engineering are given below for textile and apparel students and professionals.


                                                     Sum of average
1. Average time (in minute) = ……………………………………… ÷ 60
                                             π‘π‘’π‘šπ‘π‘’π‘Ÿ π‘œπ‘“ π‘œπ‘π‘ π‘’π‘Ÿπ‘£π‘Žπ‘‘π‘–π‘œπ‘›

2. Normal time = Average cycle time × Rating.

3. SMV =Observe time × Rating + Allowance.

                                            π‘‡π‘œπ‘‘π‘Žπ‘™ π‘œπ‘’π‘‘π‘π‘’π‘‘ ×Oπ‘π‘’π‘Ÿπ‘Žπ‘‘π‘–π‘œπ‘› 𝑆𝑀𝑉
4. Individual OP efficiency = ……………………………………….. ×100
                                                π‘‡π‘œπ‘‘π‘Žπ‘™ π‘€π‘œπ‘Ÿπ‘˜π‘–π‘›π‘” π‘šπ‘–π‘›π‘’π‘‘π‘’

                                        π‘‡π‘œπ‘‘π‘Žπ‘™ π‘π‘Ÿπ‘œπ‘‘π‘’π‘π‘‘π‘–π‘œπ‘› × π‘†π‘€π‘‰
5. Efficiency % = ………………………………………………… ×100
                         π‘‡π‘œπ‘‘π‘Žπ‘™ π‘€π‘œπ‘Ÿπ‘˜π‘–π‘›π‘” π‘šπ‘–π‘›π‘’π‘‘π‘’ ×π‘‡π‘œπ‘‘π‘Žπ‘™ π‘šπ‘Žπ‘›π‘π‘œπ‘€π‘’π‘Ÿ

                                           π‘‡π‘œπ‘‘π‘Žπ‘™ π‘π‘Ÿπ‘œπ‘‘π‘’π‘π‘‘π‘–π‘œπ‘› 𝑋 𝑆𝑀𝑉
6. Performance = ……………………………………..............……………. X 100
                         (π‘€π‘Žπ‘›π‘π‘œπ‘€π‘’π‘Ÿ ×π‘‡π‘œπ‘‘π‘Žπ‘™ π‘€π‘œπ‘Ÿπ‘˜π‘–π‘›π‘” π‘šπ‘–π‘›π‘’π‘‘π‘’)−πΏπ‘œπ‘ π‘  π‘‘π‘–π‘šπ‘’

                                            π·π‘’π‘Ÿπ‘–π‘›π‘” π‘–π‘›π‘‘π‘’π‘Ÿπ‘£π‘’π‘›π‘‘π‘–π‘œπ‘› 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦−π΅π‘Žπ‘ π‘’ 𝑙𝑖𝑛𝑒 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦
7. Efficiency Improvement = ………………………………………………........………… x 100
                                                                 π΅π‘Žπ‘ π‘’ 𝑙𝑖𝑛𝑒 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦

8. Total labor cost saved per line = Extra minute produce × cost per SAM.

                                                                                  60
9. Worker potential production per hour = …………………………
                                                                     π΅π‘Žπ‘ π‘–π‘ π‘šπ‘–π‘›π‘’π‘‘π‘’ π‘£π‘Žπ‘™π‘’π‘’

                                                                 60
10. Individual worker target per hour = ……. × π‘Šπ‘Žπ‘›π‘‘π‘’π‘‘ 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦
                                                               𝑆𝑀𝑉

                                             60
11. Line target per hour = ………… ×(π‘€π‘Žπ‘›π‘π‘œπ‘€π‘’π‘Ÿ ×π‘Šπ‘Žπ‘›π‘‘π‘’π‘‘ 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦)
                                          𝑆𝑀𝑉

                                                           π‘‡π‘œπ‘‘π‘Žπ‘™ π‘›π‘œ π‘œπ‘“ 𝑑𝑒𝑓𝑒𝑐𝑑 𝑒𝑛𝑖𝑑
12. Defect of hundred unit (DHU) = ……………………………… x 100
                                                           π‘‡π‘œπ‘‘π‘Žπ‘™ π‘–π‘›π‘ π‘π‘’π‘π‘‘π‘–π‘œπ‘› 𝑒𝑛𝑖𝑑

                               π‘‡π‘œπ‘‘π‘Žπ‘™ π‘›π‘œ π‘œπ‘“ 𝑑𝑒𝑓𝑒𝑐𝑑 𝑒𝑛𝑖𝑑
13. Defective % = …………………………………… x 100
                                π‘‡π‘œπ‘‘π‘Žπ‘™ π‘–π‘›π‘ π‘π‘’π‘π‘‘π‘–π‘œπ‘› 𝑒𝑛𝑖𝑑

                                                                                      π‘‡π‘œπ‘‘π‘Žπ‘™ π‘œπ‘’π‘‘π‘π‘’π‘‘
14. Productivity each person per hour = …………………………………………. x 100
                                                                 π‘‡π‘œπ‘‘π‘Žπ‘™ π‘€π‘œπ‘Ÿπ‘˜π‘’π‘Ÿ ×π‘‡π‘œπ‘‘π‘Žπ‘™ π‘€π‘œπ‘Ÿπ‘˜π‘–π‘›π‘” π‘šπ‘–π‘›π‘’π‘‘π‘’

                                                             π‘‡π‘œπ‘‘π‘Žπ‘™ 𝑒𝑛𝑖𝑑𝑠 π‘π‘Ÿπ‘œπ‘‘π‘’π‘π‘’ 𝑏𝑦 π‘‘β„Žπ‘’ 𝑙𝑖𝑛𝑒
15. Machine productivity = ………………..............................………………………..
                                             π‘‡π‘œπ‘‘π‘Žπ‘™ π‘›π‘œ π‘œπ‘“ π‘šπ‘Žπ‘β„Žπ‘–π‘’π‘› 𝑒𝑠𝑒 π‘‘π‘œ π‘π‘Ÿπ‘œπ‘‘π‘’π‘π‘’ π‘‘β„Žπ‘œπ‘ π‘’ π‘”π‘Žπ‘Ÿπ‘šπ‘’π‘›π‘‘π‘ 

                                          π‘‡π‘œπ‘‘π‘Žπ‘™ 𝑆𝑀𝑉
16. Basic pitch time = ………………………………
                                    π‘‡π‘œπ‘‘π‘Žπ‘™ π‘šπ‘Žπ‘›π‘π‘œπ‘€π‘’π‘Ÿ

                                                       π΅π‘Žπ‘ π‘–π‘ π‘π‘–π‘‘π‘β„Ž π‘‘π‘–π‘šπ‘’
17. Upper control limit = …………………………………………
                                         π‘Šπ‘Žπ‘›π‘‘π‘’π‘‘ π‘œπ‘Ÿgπ‘Žπ‘›π‘–π‘§π‘Žπ‘‘π‘–π‘œπ‘› 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦

18. Lower control limit = (Basic pitch time × 2) – π‘ˆπ‘π‘π‘’π‘Ÿ π‘π‘œπ‘›π‘‘π‘Ÿπ‘œπ‘™ π‘™π‘–π‘šπ‘–π‘‘

                                       π‘‡π‘œπ‘‘π‘Žπ‘™ 𝑐𝑒𝑑 π‘žπ‘’π‘Žπ‘›π‘‘π‘–π‘‘π‘¦ - π‘‡π‘œπ‘‘π‘Žπ‘™ π‘ β„Žπ‘–π‘ π‘žπ‘’π‘Žπ‘›π‘‘π‘–π‘‘π‘¦
19. Cut of ship loss % = …………………………………...……..…… ×100
                                                     π‘‡π‘œπ‘‘π‘Žπ‘™ 𝑐𝑒𝑑 π‘žπ‘’π‘Žπ‘›π‘‘π‘–π‘‘π‘¦

                                     π‘‡π‘œπ‘‘π‘Žπ‘™ π‘ β„Žπ‘–π‘π‘π‘’π‘‘ π‘žπ‘’π‘Žn𝑑𝑖𝑑𝑦
20. Cut of ship ratio = ………………………………………. ×100
                                      π‘‡π‘œπ‘‘π‘Žπ‘™ 𝑐𝑒𝑑 π‘žπ‘’π‘Žπ‘›π‘‘π‘–π‘‘π‘¦

                                                              𝑁𝑒𝑀 𝑐𝑒𝑑 π‘‘π‘œ π‘ β„Žπ‘–π‘ π‘Ÿπ‘Žπ‘‘π‘–π‘œ−π΅π‘Žπ‘ π‘’ 𝑙𝑖𝑛𝑒 π‘Ÿπ‘Žπ‘‘π‘–π‘œ
21. Cut of ship ratio improvement % = …………………..…………………………..×100
                                                                               π΅π‘Žπ‘ π‘’ 𝑙𝑖𝑛𝑒 π‘Ÿπ‘Žπ‘‘π‘–π‘œ

                                                           π‘‡π‘œπ‘‘π‘Žπ‘™ π‘ β„Žπ‘–π‘ π‘žπ‘’π‘Žπ‘›π‘‘π‘–π‘‘π‘¦
22. Receive to ship ratio = …………........................………………………… ×100
                                            π‘‡π‘œπ‘‘π‘Žπ‘™ π‘“π‘Žπ‘π‘Ÿπ‘–π‘ π‘Ÿπ‘’π‘π‘’π‘–π‘£π‘’ π‘“π‘œπ‘Ÿ π‘‘β„Žπ‘’ π‘œπ‘Ÿπ‘‘π‘’π‘Ÿ (π‘†π‘ž.𝑦𝑑𝑠)

23. Total financial saving = Number of extra pieces shipped × Average FOB

                                                   π΄π‘£π‘’π‘Ÿπ‘Žπ‘”π‘’ 𝑒π‘₯𝑝eπ‘›π‘‘π‘–π‘‘π‘’π‘Ÿπ‘’ π‘œπ‘“ π‘‘β„Žπ‘’ π‘“π‘Žπ‘π‘‘π‘œπ‘Ÿπ‘¦
24. Cost Per Minute (CPM) = …………………………............………………..
                                                    π΄π‘£π‘’π‘Ÿπ‘Žπ‘”π‘’ π‘ƒπ‘Ÿπ‘œπ‘‘π‘’π‘π‘’ π‘‘π‘–π‘šπ‘’ (π‘€π‘œπ‘›π‘‘β„Žπ‘™π‘¦)

25. Cost of Manufacture (CM) = SMV × CPM

                                                                  π‘‡π‘œπ‘‘π‘Žπ‘™ π‘œπ‘’π‘‘π‘π‘’π‘‘ ×𝐢𝑀 π‘π‘’π‘Ÿ π‘”π‘Žπ‘Ÿπ‘šπ‘’π‘›π‘‘π‘ 
26. CM earned per person per hour = ………………….....………………………….
                                                               π‘‡π‘œπ‘‘π‘Žπ‘™ π‘€π‘œπ‘Ÿπ‘˜π‘’π‘Ÿ ×π‘‡π‘œπ‘‘π‘Žπ‘™ π‘€π‘œπ‘Ÿπ‘˜π‘–π‘›π‘” π‘šπ‘–π‘›π‘’π‘‘π‘’

27. Monetary Loss due to cut ship loss in month = (Total number of produced garments in month × cut to ship loss percentage for a month × Average FOB of the style)

28. Monetary Loss due to cut ship loss in style wise = (Total number of produced garments in the style × cut to ship loss percentage for a month × Average FOB of the style)

                                                π‘‡π‘œπ‘‘π‘Žπ‘™ π‘šπ‘Žπ‘›π‘π‘œπ‘€π‘’π‘Ÿ
29. Man & machine ratio = ……………………………………
                                               π‘‡π‘œπ‘‘π‘Žπ‘™ π‘šπ‘Žπ‘β„Žπ‘–π‘›π‘’

                              π‘‡π‘œπ‘‘π‘Žπ‘™ π‘›π‘œ π‘œπ‘“ π‘Žπ‘’π‘‘π‘–π‘‘ π‘“π‘Žπ‘–π‘™
30. Audit fail % = ………………………………….×100
                                π‘‡π‘œπ‘‘π‘Žπ‘™ π‘›π‘œ π‘œπ‘“ π‘Žπ‘’π‘‘π‘–π‘‘

31. Earned minute = Total production X SAM

                                                            π‘‡π‘œπ‘‘π‘Žπ‘™ β„Žπ‘’π‘Žπ‘‘π‘π‘œπ‘’π‘›π‘‘−π‘π‘œ π‘œπ‘“ π‘šπ‘Žπ‘β„Žπ‘–π‘›π‘’ π‘œπ‘π‘’π‘Ÿπ‘Žπ‘‘π‘œπ‘Ÿπ‘ 
32. Factory direct & indirect ratio = …………………………………………………….
                                                                            π‘‡π‘œπ‘‘π‘Žπ‘™ π‘›π‘œ π‘œπ‘“ π‘œπ‘π‘’π‘Ÿπ‘Žπ‘‘π‘œπ‘Ÿπ‘ 

                                                      π‘‡π‘œπ‘‘π‘Žπ‘™ π‘ π‘Žπ‘™π‘Žπ‘Ÿπ‘¦ π‘œπ‘“ π‘‘β„Žπ‘’ π‘™π‘Žπ‘π‘œπ‘Ÿ 𝑖𝑛 π‘‘β„Žπ‘’ π‘šπ‘œπ‘›π‘‘β„Ž
33. Labor cost per minute = ……………........……………………………………….
                                               π‘‡π‘œπ‘‘π‘Žπ‘™ 𝑆𝐴𝑀 π‘π‘Ÿπ‘œπ‘‘π‘’π‘π‘’ 𝑏𝑦 π‘‘β„Žπ‘œπ‘ π‘’ π‘™π‘Žπ‘π‘œπ‘Ÿπ‘  𝑖𝑛 π‘‘β„Žπ‘Žπ‘‘ π‘šπ‘œπ‘›π‘‘β„Ž

                                                            π‘π‘œ π‘œπ‘“ π‘šπ‘Žπ‘β„Žπ‘–π‘›π‘’ π‘Žπ‘ π‘ π‘–π‘”π‘›π‘’π‘‘ ×π»π‘œπ‘’π‘Ÿπ‘™π‘¦ π‘‘π‘Žπ‘Ÿπ‘”π‘’π‘‘ π‘žπ‘‘y
34. Estimated production per hour = …………………………………………………………….
                                                                        πΆπ‘Žπ‘™π‘π‘’π‘™π‘Žπ‘‘π‘’π‘‘ π‘›π‘œ π‘œπ‘“ π‘šπ‘Žπ‘β„Žπ‘–π‘›π‘’π‘ 

                                                              π‘‡π‘œπ‘‘π‘Žπ‘™ π‘šπ‘–π‘›π‘’π‘‘π‘’ 𝑖𝑛 π‘Ž π‘ β„Žπ‘–π‘“π‘‘ ×𝐿𝑖𝑛𝑒 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦
35. Estimated machine productivity = ………………………………………………………..
                                                                                 πΊπ‘Žπ‘Ÿπ‘šπ‘’π‘›π‘‘π‘  𝑆𝑀𝑉

                                         π‘Šπ‘œπ‘Ÿπ‘˜π‘’π‘Ÿ π‘π‘œπ‘‘π‘’π‘›π‘‘π‘–π‘Žπ‘™ π‘π‘Ÿπ‘œπ‘‘π‘’π‘π‘‘π‘–π‘œπ‘› 𝑃.𝐻 - πΆπ‘’π‘Ÿπ‘Ÿπ‘’π‘›π‘‘ π‘π‘Ÿπ‘œπ‘‘π‘’π‘π‘‘π‘–π‘œπ‘› 𝑝𝑐𝑠 𝑃.𝐻
36. Productivity Gap % = ………………….……………..................………………………… ×100
                                                          πΆπ‘’π‘Ÿπ‘Ÿπ‘’π‘›π‘‘ π‘π‘Ÿπ‘œπ‘‘π‘’π‘π‘‘π‘–π‘œπ‘› 𝑝𝑐𝑠 π‘π‘’π‘Ÿ β„Žπ‘œπ‘’π‘Ÿ

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