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Showing posts from October, 2014

Why to Develop Database for Learning Curve? (When You would not be Getting Repeat Order)

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On the post"How to Calculate Production Target and Worker’s Bonus on Initial Days of Production Start?", I am asked this question, "Is there any benefit of developing a database in such case where style does not repeat?"



This is a good question. And you should also know why one should develop a database when there is no chance of getting repeat orders. In the following, I have briefly explained the benefits of creating a database. Though I have mentioned creating a database for the learning curve this thing is true for preparing the database for other areas too.


Based on Pareto's  principle (80-20 rule), you will find 80% similar operations in new styles, though you are not getting repeat order of a style (I am assuming that you will be working same product or similar product range). In production similar machines will be used to make the new styles - 80% machine will same as used in earlier styles. Also, most of your sewing operators are same. So, don't th…

Benefits of Single-Piece Flow Production System

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Single-Piece Flow system is one of the many garment production systems. In Single-Piece Flow system only one garment is processed at a time through various operations in a sewing line. This production system is also known as a one-piece flow system. A single-Piece flow system is considered as a part of the lean manufacturing system. So, lean philosophy is applied when one uses a single-piece flow system.

Like other production systems, this production system has a number of merits and demerits. In this article, I will explain the merits of the Single-Piece Flow production system related to the garment industry. Benefits explained in the following are irrespective of lean manufacturing.

Involvement of Industrial Engineers in Cutting Department of a Sewing Factory

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What all activities Industrial Engineer can do in cutting department? - This question was asked by one of the OCS readers. 

In this post, I have answered this question with the possible involvement of IE departments in the cutting department.

In the garment industry Industrial Engineers (IE) mainly focus on the sewing department of a factory. IEs perform various activities in the sewing floor and improve production processes. IE skills and knowledge can be applied in the other departments too, like cutting department and finishing department in a garment factory.

How will You (Industrial Engineers) Improve Efficiency of a Sewing Line?

In this post, I am going to ask you one question - being an Industrial Engineer, how will you improve the efficiency of a sewing line?

Or if you have already improved line performance earlier then how did you achieve that improvement?

(Note: Line performance to be measured in efficiency percentage).

The primary goal of employing an Industrial Engineer in a company is to reduce production cost and improve product quality. Production cost per garment is directly linked to factory efficiency when other parameters like workers salary are fixed. It means when you increase line efficiency (labour productivity) production cost per garment goes down.

Application of IE Concepts in Finishing Section in Garment Factories

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Question:  I am working as Asst. Officer (IE) at ABC Fashion Ltd. I just want to know the application of IE in the finishing department? I mean what we can do as IE in the finishing department? It will be very helpful if you reply me back. Thanks …asked by Hasan.

You are an Industrial Engineer. You already know about industrial engineering tools and techniques used for managing and improving production. Most IEs practice IE concepts only in sewing floor. Similar tools can be applied in finishing section also. In the following, I have listed down few things that can be done in finishing department without further brainstorming and skill upgrading.




Setting of Standard Time (SAM) for finishing jobs (activities)- Like sewing operations, estimate SAM for finishing jobs. Use Time Study method or synthetic data (PMTS) for determining SAM of a task. Prepare operation sheet for finishing section also. By setting SAM of finishing job, you can plan finishing production accurately; you can estima…

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