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Basic Industrial Engineering Terms
Basic Industrial Engineering Terms
ENGINEERING TERMS
WHAT IS INDUSTRIAL ENGINEERING ?
SMV defined as " Time taken by a standard worker to perform the task with pre-defined conditions"
SMV = BASIC TIME + (BASIC TIME × ALLOWANCE)
Suppose to complete an operation, an standard operator takes 1 minute.
We put 15% allowance(Men, M/c & Time)
SMV=1+(1×.15) Min
=(1+.15) Min
=1.15 Min
GMT SMV is the sum of SMV for all M/c & Manual operation to complete an item
RELATED TERMS TO SMV(Cont..)
Standard Operator : For a specific item & style, the potential operator who can give
maximum output with best quality & can improve productivity.
Lets see an Example for better understanding, Minimum • Suppose 100
Pcs Cutting
Input
I. Batsman faces 10 balls to score 5 Runs Input
Pre-defined Conditions : On time input arrival, single piece flow, running m/c conditions,
defined quality status etc. are called pre-defined conditions.
Basic Time : Actual time to complete an operation. In other word, basic time is the pick
& drop time including operation for quality output.
Basic Time= Pick time + Operation + Drop time;
Result , Input=Output with required quality
In a broad sense , a GMT SMV=Sum of all operation SMV, not SMV of GMT + allowance.
EFFICIENCY
Suppose any GMT item SMV is 5.5 (For any fixed style SMV always fixed)
We use 22 Manpower(Operator & Helper) to achieve 1500 Pcs for 10 hour working shift
EARNED MINUTE = 1500× 5.5 or 8250 Min
AVAILABLE MINUTE = 22× (10×60) or 13200 Min
EFFICIENCY = 8250 Min/13200 Min or 0.625
Efficiency is expressed as % ,Then EFFICIENCY =(0.625 ×100)% or 62.50%
Efficiency is a ratio , not a number.
Efficiency vary with LEAD TIME & QUANTITY . More Lead time & Quantity Increase
Efficiency , on the other hand less lead time tends us to use more MP or time to get
required output , so efficiency reduces.
LINE TARGET
i. 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
ii. Qty of running Machine of your factory of the following month (which total expenditure we have consider
here). Suppose -100 machines.
iii. Number of machine to complete the layout for the following Items (which CM we are calculating). Suppose-
25 machines.
iv. Production target/capacity of the following items, per hour from the existing layout, excluding alter & reject.
Suppose-200 pcs per hour.
v. Total working day of the followings month,(though the house rent, commercial expenses, machine
overhauling & some other cost remain same) Suppose-26 days.
COST OF MAKING (CM) RULE:
={(Monthly total expenditure of the following factory/ 26) / (Qty of running Machine of your factory of the
following month) X (Number of machine to complete the layout)} / [{(Production capacity per hr from the existing
layout, excluding alter & reject) X 8}] X 12 / (Dollar conversion rate)
= [{(50,00,000 / 26) / ( 100) X (25)} / {(200) X 8}] X 12 / 74
= [{192307.7 / (100) X (25) } / 1600] X 12 / 74
= (48,076.9 / 1600) X 12 / 74
= 30.048 X 12 / 74
= 360.58 / 74
= $4.873 / dozen (this is the making cost (12 pcs) of the following items)
However, 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 $16.216 to $18.92/per day. Above
is for a non-compliance factory.
For the a compliance factory the per day machine cost will be 1800 tk to 2100 tk
( $24.32 to $28.37)
SO, if the an items produce 1600 pcs per day using 25machines then the CM will be
= Overhead machine cost X require machine / produce quantity X 12 / $74
= 1400 X 25 / 1600 X 12 / 74
= $3.547/DOZ
CONVENTIONAL VS MODERN PROFIT THEORY
Conventional :
COST + PROFIT = PRICE
Modern :
PRICE – COST = PROFIT
TIME STUDY : A WORK MEASURING TECHNIQUE TO CALCULATE BASIC TIME BY FINDING CYCLE
TIME & ADDING ALLOWANCE
MOTION STUDY : A TECHNIQUE TO ANALYZE OPERATORS MOTION & SET STANDARD BY
ELIMINATING UNNECESSARY MOTION
TWO DIFFERENT THEORY BUT NEED PARALLEL RUNNING TO IMPROVE SYSTEM KNOWN AS
‘METHOD ENGINEERING’
TIME & MOTION STUDY IS A CONJUGAL TECHNIQUE TO PROCESS CONTROL,IMPROVE DISSIMILAR
WORK PERFORMANCE & SET STANDARD GOALS
‘’IE IS A COMBINE PACKAGE TO IMPROVE BY TIME STUDY,WORK STUDY & MOTION STUDY’’
LINE BALANCING
FIND METHOD
LINE CAPACITY CAPACITY LINE
BOTTLENEC ENGINEERIN
LAYOUT STUDY GRAPH BALANCING
K G
STEPS FOR LINE BALANCING
‘BOTTLENECK’ (CONSTRAINT M/C OR MP OR OPERATION THAT REDUCES PRODUCTIVITY) HAVE TO FIND
OUT
FIND OUT OPERATION TO BALANCE WITH BOTTLENECK BY CHECKING WITH HIGER CAPACITY
ELIMINATING NON VALUE ADDED TIME & SAM & CAPACITY CALCULATION
1 Front n back n 1st shoulder join with / without tape 4TH/OL 2 162 162 NO
4 2nd shoulder join with / without tape 4TH/OL 1 180 160 BALANCE (6) 20 PCs/HR
6 Sleeve n body match n insert sleeve 4TH/OL 2 140 160 BALANCE WITH (4)
8 Side/ sleeve Seams inc. care label and Gmts turns 4TH/OL 2 160 160 NO