Industrial engineering

in

apparel production

V Ramesh Babu

WOODHEAD PUBLISHING INDIA PVT LTD

New Delhi
Cambridge Oxford
Philadelphia
 Contents

Preface ix

Acknowledgements xi

1 Concepts of production and productivity 1

1.1 Introduction 1

1.2 Production 2

1.3 Productivity 5

1.4 Standard of living 8

1.5 Productivity measures 11

1.6 References 13

2 Role of apparel engineering 15

2.1 Introduction 15

2.2 Apparel engineering 16

2.3 Methodology 17

2.4 Benefits of engineering 18

2.5 Tools and techniques for apparel engineering 18

2.6 Role of industrial engineer 21

2.7 Pre-production activities of a

supervisor 24

2.8 References 28

3 Method analysis 29

3.1 Definition 29

3.2 Recording the method 31

3.3 Operation process chart 33

3.4 Flow process chart 35

3.5 Flow diagram 37

3.6 String diagram 38

3.7 Travel chart (From -

To chart) 40

3.8 Multiple activity chart (or) man-machine chart 44

 Contents
VI

45
3.9 References
47
4 Motion economy
47
4.1 Principles of motion economy
50
4.2 Two-handed process chart

4.3 Micro motion study

55
4.4 Study of method recorded
60
4.5 Methods improvement
62
4.6 References

and 63
5 Apparel production systems factory layout
63
5.1 Introduction
63
5.2 Garment production systems
64
5.3 Group system
line system batch system 66
5.4 Progressive bundle synchro straight -

69
5.5 Unit production system (UPS)
71
5.6 Quick response sewing system
72
5.7 Layout objectives
74
5.8 Designing the layout
5.9 References 77

6 Work measurement 79

6.1 Definition of work measurement 79

80
6.2 Techniques of work measurement
6.3 Time study 87

6.4 Selecting the job 91

6.5 Standard allowed minute (SAM) 96

6.6 Rating factor 100

6.7 Allowances 104

6.8 Other methods to set time standards 108

6.9 References U2

7 Application of IE techniques in garment industry H3

7.1 Capacity study 113

7.3 Operator performance U5

7.4 Follow-ups IJ -y

7.5 Work in process (W1P) 120

Contents vii

7.6 Operation bulletin 122

7.7 References 127

8 Line balancing 129

8.1 Balancing 129

8.2 Steps to balance the line 131

8.3 Initial balance 134

8.4 Balance control (Operating a line) 140

8.5 Efficiency 142

8.6 Cycle checks 143

8.7 Balancing tools 145

8.8 References 151

9 Scientific method of training 153

9.1 SMT (Scientific method of training) 153

9.2 Methodology behind SMT 155

9.3 Selection test 159

9.4 Basic exercise 161

9.5 Paper exercise 162

9.6 Fabric exercise 163

9.7 References 168

10 Industrial engineering in apparel quality control 169

10.1 Introduction 169

10.2 Quality is a multi-dimensional aspect 171

10.3 How to control quality? 172

10.4 How to achieve good quality? 174

10.5 Quality specifications sheet 175

10.6 Quality training 176

10.7 References 179

Index 181