Concept of IE (industrial engineering)

The garment manufacturing and exporting industry is facing heavy challenges due to various factors including global competition, production costs increase, less productivity/efficiency, labor attrition, etc. the basic fact that our country has immense strength in human resources itself is the motivating aspect to feel for such an analysis. For overcoming those challenges our need industrial engineering knowledge.

Industrial engineers (IEs) are responsible for designing integrated systems of people, machines, material, energy, and information. Industrial engineers figure out how to do things better. They engineer processes and systems that improve quality and productivity. They work to eliminate waste of time, money, materials, energy, and other resources. This is why more and more companies are hiring industrial engineers and then promoting them into management positions. .

We can see at a glance of IE,

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

I’m giving some formula for Industrial engineering students or professionals. If those help them then I will be thankful.

6. Standard Pitch Time (S.P.T) = Basic Pitch Time (B.P.T) + Allowances (%)

7. GSD
GSD = (Man power * Work hour) / Target

8. SMV
SMV = Basic time + (Basic time * Allowance)

9. Basic time
Basic time = Observed time * Rating

10. Observed time
Observed time = Total Cycle time / No of cycle

11. Rating
Rating = (Observed Rating * Standard rating) / Standard rating

12. Earn minute
Earn minute = No of Pc’s (Production) * Garments SMV

13. Available minute
Available minute = Work hour * Manpower

14. Organization Efficiency
Organization Efficiency = (Basic pis time / Bottle neck time) * 100

15. Basic pis time (BPT)
Basic pis time = Total GMT SMV / Total Manpower

16. UCL
UCL = Basic pis time / Organization Efficiency

17. LCL
LCL = 2 * Basic pis time – UCL

18. Capacity
Capacity = 60 / Capacity time in minute

19. Cycle Time
Cycle Time = 60 / Team target

20. Capacity Achievable
Capacity Achievable = Capacity * Balance

21. Daily output
Daily output = Work hour / SMV

22. Factory capacity
Factory capacity = (Work hour / SMV) * Total worker * Working day * Efficiency

23. CPM
CPM = (Total over head cost of the month / No of SMV earners Work minutes) *Efficiency

24. Required no of operator
Required no of operator = Target daily output / Daily output per operator

25. Efficiency
Efficiency = (Earn minute * Available minute) * 100 

- See more at: http://textilecalculation.blogspot.com/2014/11/some-important-formula-for-industrial.html#sthash.ULNjBipl.dpuf

How to Calculate Standard Allowed Minutes (SAM or SMV) inGarments Industry?

Email: marzuk.suad@gmail.com

Introduction:

Standard Allowed Minute or Standard Minute Value (SAM or SMV) is an important factor in garments manufacturingindustry. Production rate can be calculated by using it. But Standardminutes (SAM or SMV) estimation is not a tough task that we have normally seemed. As its importance on readymade garments industry, today I willpresent here the estimation method of SAM or SMV.

Calculation Method of Standard Minute (SAM or SMV) in Apparel Industry:

An industrial engineer should follow the below formula for calculating SAM or SMV.
SAM = (Basic minute + Bundle allowances + Machine and Personal allowances)…… (1)
Normally bundle allowances should be added 10% with basic time and Machine and Personal allowances added 20% with basic time.
The main thing here, the determination of “Basic minute”. It can be done by two ways. Both ways have discussed in this article.

Method-01:
In this case, SAM or SMV Calculation can be done by using synthetic data. At first an industrial engineer has to fix anoperation, for which he wants to estimate SAM or SMV.http://garmentsstudybd.blogspot.com

Here, he should stand near the m/c operator and follow the every working procedure for the selected operation. He should note all the activities done by the operator (these activities are called synthetic data collection). When all the activities of operator will complete, then industrial engineer should follow the same activities of operator again to check the noted activities that the note is ok or not.

Now, industrial engineer should list down all the activities of operator in sequentially and refer the synthetic data for TMU (time measuring unit) values. Suppose, industrial engineer got TMU value for that operation is 450. Now he should convert total TMU into minutes, where (1TMU= 0.0006 minute). So for 450TMU= (450 × 0.0006) = 0.27minute. This minute is termed as Basic time.

So, now from equation-01, we get,
SAM or SMV = (Basic minute + Bundle allowances + Machine and Personal allowances)



= 0.27 + (0.27 × 10%) + (0.27 × 20%)
= 0.27 + 0.027 + 0.054
= 0.351minute

So, SAM or SMV value for that operation is 0.351 minute.
Method-02:



In this case, SAM or SMV Calculation can be done by using time study.

Here, industrial engineer should take a stop watch and stands near the m/c operator. Capture cycle time for that operation (that he chosen early). Cycle time means “total time needed to complete full operation”. He should be done this process consecutively at least for 5 cycle times. Then he should calculate mean cycle time by adding 5 cycle times and divided those by 5. Finally industrial engineer gets the cycle time here. (Let, cycle time here 0.50) Now, he should convert cycle times into basic time by multiplying with “performance rating”.

So, Basic time = Cycle time × Performance rating ………………. (2)

Performance rating:

Performance rating is related with m/c operator. In which speed, operator completed his duty. It’s determined by industrial engineer. Let, the operator performance rating was- 70%.
So, from equation (2), we get,
Basic time = 0.5 × 70% [Cycle time= 0.5] = 0.35

So, basic time= 0.35
By using equation- (1), now we get,
SAM or SMV = (Basic minute + Bundle allowances + Machine and Personal allowances)
= 0.35 + (0.35 × 10%) + (0.35 × 20%)
= 0.35+ 0.035 + 0.07
= 0.46 minute

So, SAM or SMV for that operation stands at 0.46 minute.

Calculate the CM (Cost of Making) of a Garment

Calculatethe CM (Cost of Making) of a Garment

HM MARZUK RUHAN

B.Sc. in TEXTILE
MIS
SUAD GARMENTS INDUSTRIES LTD, Narayongonj
Email: marzuk.suad@gmail.com

Introduction:


Normally at present (after starting the new salary scale) in Bangladesh we calculate the CM of any item consider the overhead sewing machine cost 1200 tk to 1400 tk/day that means $15.38 to $17.95/per day.

Above is for a non-compliance factory. For a compliance factory the per day machine cost will be 1800 tk to 2100 tk ( $23.08 to $26.92).

Example :

If an items produce 1600 pcs per day using 25 machines then what would be the CM cost ???

Solution:
CM cost = Overhead machine cost X require machine / produce quantity X 12
= (1800 X 25 / 1600 )X 12
= 337.5 Taka
= $ 337.5/78
= $ 4.32 /dozen

Calculate the CM of a Garment

Calculate the CM after discussion with your production department. It’s vary depends on require machine qty & output qty.

Garments making

To find out the CM of a item you must need the following 06 (six) information at first, as listed below

• Monthly total expenditure of your factory with factory rent, commercial cost, electricity bill, water bill, transportation, repairing, worker & stuff wages etc. (8hrs/day) in bangla taka. Suppose-50,00,000/tk 

• Qty of running Machine of your factory of the following month (which total expenditure we have consider here).Suppose- 100 machine.

• Number of machine to complete the layout for the following Items (which CM we are calculating). Suppose - 25 machines . 

• Production target/capacity of the following items, per hour from the existing layout, excluding alter & reject. Suppose 200 pcs per hour. 

• Total working day of the followings month,(though the house rent,commercial expenses, machine overhauling & some other cost remain same)Suppose- 26 days. 

• If you want to calculate the CM in US$ (dollar) then pls input present dollar conversation rate BDTk. Suppose $1 = 78 tk.

COST OF MAKING (CM)

=(SAM of the garment * Minute cost of the labor) / Line efficiency (%)

OR

= Overhead machine cost X require machine / produce quantity

= [{Monthly total expenditure of the following factory / (26 X Qty of running Machine of your factory of the following month)}] X (Number of machine to complete the layout) / produce quantity per day.

= [{50,00,000 / (26 X 100 )} X 25] / {(200) X 8}] X 12

= [{192307.7 / (100) X (25) } / 1600] X 12

= (48,076.9 / 1600) X 12

= 30.048 X 12

= 360.58 Taka

= $ 360.58/ 78

= $ 4.62/dozen

This is the making cost (12 pcs) garments.

- See more at: http://textilecalculation.blogspot.com/2014/11/calculate-cm-cost-of-making-of-garment.html#sthash.xJM627DO.dpuf