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Showing posts from March, 2013

Frequently Asked Questions in Industrial Engineering Job Interviews [Discussion Post]

I guess you, being an IE or ex-IE; have given job interviews in your current organization and in those organizations where you have worked earlier. On the other hand, you may also have taken a lot of interviews at the time of hiring your subordinates or work-study team members. You asked a set of questions to the candidate to judge the technical skills and personal skills of the candidate. On the other hand, you had been asked many questions by interview panelists when you have given interview for a job. I am inviting you please participate in this discussion.

Our discussion topic: What questions are frequently asked by interview panelist in a job interviews for IE selection?

Purpose of the Discussion: This discussion will help entry level IEs to prepare themselves for the job interviews. We can help each other to build a ‘Question Bank’ that would enrich our knowledge. I’m writing an E-book on this topic, I am planning to select critical and common questions from your your questio…

How Factory Overhead Cost is Calculated in Garment Export Business?

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Question: I would like to know, how to calculate overheads? Because so many times I have seen that merchants are using a fixed number as overheads. When I ask them how they got this number, they failed to give a satisfactory answer. Please give a brief description. It will be helpful for not only me but also so many new merchants. ... asked by Alok De

When you are making a garment for export orders you should know correct method of costing your product.

Secondly, what are the cost factors to be included to have complete cost?

At the time product cost estimation actual figures are considered for direct material cost and actual direct labor cost. But for the overhead cost, a percentage of direct labor cost (overhead ratio) is considered in costing calculation. 

Here is the formula, 
Garment manufacturing cost = (Direct Labor cost + Direct Material Cost + Factory Overhead)

Where overhead = x % of direct labor cost

Now the question is how do you find the value of x?

In this article, I hav…

Types of Machines Used in a Shirt Making Factory

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Question: I want to know which types of machines are used in a shirt factory and what are their costs. ... asked by Tarun Gaur

The shirt is one of the basic products of our clothing range. A shirt can be made by a single machine but to construct a branded shirt (Quality Shirt), shirt-making factories and export houses use different types of machines to sew different part of the garment (seams). Many factories use special machines also for the front placket and side seam and underarm sewing. The main purpose of using different types and special machines is to maintain a certain quality level of the product and to increase productivity.

Name of the different sewing and non-sewing machines and operations done with those machines are shown below respectively. Note: Use of machine types may vary based on the styling of seam types in a shirt used in the same operations.
Sewing MachinesSingle Needle Lock Stitch (Plain, with/ without UBT): Collar and Cuff making, Pocket hemming and pocket at…

H&M Makes Its Global Supplier Factory List Public

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H & M (Hennes & Mauritz AB) a Sweden based company was founded in 1947. The H&M Group has around 2,800 stores in 48 markets including franchise markets.

H&M is one of the first and largest fashion companies in the world to make its supplier factory list public.

As per H&M "The list includes all our supplier factories with which we have a long term business relation – and thereby around 95% of our order volume for all our brands."
A screenshot of the supplier list is shown in the following.

Sample Operation Breakdown of a Jacket

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A sample operation breakdown with SAM of each operation has been shown below. In this article, only operation breakdown and operation SMVs are posted. Production layout will be posted in a separate article.
Standard time shown in the below chart is determined from Time Study. List of operations and SAM of operations may vary based on style and construction. This Operation breakdown has been sourced from a graduation project report of a NIFT student. This Project was done in Silver Sparks Apparel Limited, Bangalore.

Selection of Improvement Projects and Project Implementation Method

A couple of months ago, when I published the article Top 9 projects topics for apparel production students, I had received a request from readers to write an article on “Topics for mini-projects for the IE”. This article is for those who are planning to do an improvement project in their factory or departmental level by themselves.

I can suggest you many topics that can be taken as improvement projects. But just suggesting a topic does not make any sense. Because every factory is unique in term of problems faced by them. What all problems you faced need to be solved one by one. Solving a problem in a proper method is a project. You should do an improvement project that is essential to improve your departmental performance as well as factory performance. So I would suggest you first learn how to select the right topic for mini projects (improvement projects) in your factory or within a department. Then go for implementation of that project with the predefined project plan.

I will …

What are the Different Steps Involved in Cutting, Sewing and Finishing departments?

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Departments such as Cutting, Sewing and Finishing are primary departments of a garment factory. The name of the departments itself explains that what are the main functions of these departments. Within each department there are number of steps through which raw materials are passed to make a finished and packed garment. These steps or sub-processes may vary product to product. Most common steps in each departments in apparel industry have been listed below.

Take a Virtual Tour of Modern Apparel Manufacturing Companies

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Most of us rarely get chance to visit garment factories those are equipped with latest machinery and state of art technology. On Youtube you can watch such videos of top level factories. Many apparel manufacturing companies have posted their company profile on Youtube with shop floor workflow, various departments and latest machinery . You can take virtual tour of those factories on Youtube.

I have picked two such videos and embedded below. Watch and Enjoy!

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