Industrial Engineering And Operations Management

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Proceedings of the International Conference on Industrial Engineering and Operations ManagementRabat, Morocco, April 11-13, 2017Industrial Engineering and Operations ManagementFunctions in the Apparel Manufacturing IndustryMd. Atikul IslamFirst Senior Assistant DirectorWalton Micro-Tech CorporationChandra, Kaliakoir, Gazipur, Bangladeshatikiem@gmail.comMd. Sunny Ul IslamDeputy DirectorWalton Micro-Tech CorporationChandra, Kaliakoir, Gazipur, BangladeshSun kuet@yahoo.comJiku Das GuptaFirst Senior Assistant DirectorWalton Micro-Tech CorporationChandra, Kaliakoir, Gazipur, Bangladeshjikuiem@yahoo.comAbstractThe role of Industrial Engineering Department (IED) is very crucial in improvement of factoryperformance. The involvement of Industrial Engineers (IE) starts from sampling stage through productanalysis to ensure the sample sent for approval is most suited for bulk production. The IED forms thebackbone of the entire factory operations by setting production targets and defining methods that need tobe followed in the shop floor. The responsibility of IED is to maximize overall efficiency of themanufacturing functions through provision of an effective, appropriate and timely work study andIndustrial Engineering service and maintenance of an ideal production environment. The key tasksincludes product analysis through determining optimum method of construction and establishingOperation Bulletin (OB); product costing by determining standard minute cost of each operationspecifying the equipment type and work aids used; production planning for effective and balanced flow ofproduct; operator performance monitoring systems by hourly production monitoring and skill matrix; offstandards of different functions and implement methods to reduce; method; justify all changes based onanalysis of work content; continuous improvement; taking cost saving opportunities; monit or operatorperformances and take action to improve performances and eliminate causes of underperformance.KeywordsIndustrial Engineering Department, Industrial Engineer, Operation Bulletin, Production Planning, Off-Standards1. IntroductionRole of the Industrial Engineering and Operations Management functions is crucial in imp rovement of factoryperformance. Involvement of Industrial Eng ineer starts at the sampling stage where he would be involved in productanalysis. This analysis is carried out to ensure that the sample sent for approval is most suited for production. Thisdepartment forms the backbone of the entire factory operations by setting production targets and defining themethods that need to be followed on the shop floor.886

Proceedings of the International Conference on Industrial Engineering and Operations ManagementRabat, Morocco, April 11-13, 2017In case of apparel manufacturing industries where thousands of peoples are involved for production and majority ofthe tasks involves manual and semi-auto mated tasks industrial Eng ineering and operations management techniquesprovides the most valuable output within shorter time. Tradit ionally, most of the persons involved in apparelmanufacturing were not aware of costings involved with the production. But day by day with increasing costings ofraw materials and worker’s salary, the use of industrial Eng ineering and Operat ions Management techniquesbecomes vital for required production quantity, desired quality and on time production process.If we analyze the history of top class industries, they were pushed to employ the Toyota production system, bundleproduction system, just in time manufacturing, total productive maintenance, tot al quality management, 5s, sixSig ma, lean manufacturing etc. which are just the industrial Engineering tools that giving the best output atminimum cost within shorter period of time.Now a day any production system without operations management and industrial Engineering functions impossibleto sustain. The ultimate benefits coming from these implementations is the maximu m use of labors and cost savings.The major responsibility who are handling these types of activities includes maximizing the overall efficiency of themanufacturing functions through provision of an effective, appropriate and timely work study and industrialengineering service and maintenance of an ideal production environment.2. MethodologyIn order to maximize the overall efficiency of the manufacturing functions it requires to perform some key taskswhich may be summarized as follows:Key Tasks Product Analysis:o Determining optimum method of construction to achieve required finished product efficientlyo Establish operation bulletin Product Costing: Determine the standard minute “cost” of each operation specifying the equipmenttype and work aids to be used Production Planning: Provide a line p lan for effective, balanced flo w of the product, incorporating lineand individual (operation) productivity standards Operator Performance: Develop operator performance monitoring systems by the means of hourlyproduction monitoring, gum-sheet and skill matrix etc. Off-standards: Analyze d ifferent factors of increasing off-standards in the factory and imp lementmethods to reduce it Performance Development: Apply industrial engineering techniques to develop the performance ofteams and individuals Method Engineering - Develop detailed man and material movement methods. Document all methodsusing manual, co mputer based or video/visual systems as appropriate. Justify all changes based onanalysis of the work content in the operation, taking account of the skill requirements Maintenance: Ensure that production methods, production equipment and workp laces, work-study dataand time standards are effectively and rigorously maintained Continuous Improvement:o Constantly review production methods to identify and take cost saving opportunitieso Constantly monitor operator performances against time standards and targets and take action toimprove performances and eliminate causes of under performanceIn case of apparel manufacturing the key tasks mentioned above is crucial in all stages. During the study a reputedapparel manufacturing industry was chosen and the overall functions has been understood at each stage and forimplementation these functions these are documented using block diagram and responsibilit ies given to respectivedepartments.887

Proceedings of the International Conference on Industrial Engineering and Operations ManagementRabat, Morocco, April 11-13, 20173. Research and Findings of the StudyThe overall Industrial Eng ineering and Operations Management study functions have been shown and exp lained atseveral sections of apparel manufacturing depending on the requirements.3.1 Sampling & Pre -Production Standard Operating ProceduresThe Sampling & Pre-Production Starts from order entry from merchandizer and goes throughpreparation of operation bulletin, target production, thread-fabric-accessories consumption, ppsample approval, order confirmation and after subsequent changes finishes through pp meetingas shown in Figure-1.Tech-PackInitial OBOrder Enquiry SheetOrder Entry forCostingPreparation of InitialOBCalculation ofTarget Productionper hourThreadConsumption,Manpower &MachineCalculationCalculation ofFabric & AccessoryConsumption bySamplingPP SampleApprovalSamples Preparation(Fit, Sealer, PP etc.)Order ConfirmationOrder Enquiry SheetSent toMerchandiserOrder EntryMeetingDailyProductionReportStyle StatusReportMOM-PP MeetingProposedConstructionChanges ReportFinal OBChanges in OB asper PP SamplePP MeetingIE ActivitiesFigure 1: Sampling & Pre-Production SOPThe whole responsibilities of department responsible and necessary coordination has shown inTable 1.Table 1: Responsibilities of Different Persons according to SOPSLNo1234567TasksMerchandiser requests for various details regarding initial costing purposefrom production team.A sample or sketch of the style with all the construction details must bereceived by the Industrial Engineering department. This sketch and allconstruction details must be sent in hard copy and also soft copy should besent via e-mail to IE Head cc to GM-Production, IE-Head & ProductionPlanner and Sampling Department Head.Depending on product details, IE-Sampling prepares an Initial OperationBulletin (OB) which contains all product related operations andrequirementsOn the Basis of the Initial Operation Bulletin, IE Sampling calculates thetarget production per hour and total number of hours required to completethe order.Once the target production per hour is finalized, different requirements(thread consumption, Manpower & Machine requirements, etc.) arecalculated by IE - Sampling.Simultaneously, Sampling Team calculates consumption for the fabric andsewing accessories (lace, tape, etc.), which is then reviewed by IE Sampling.IE-Sampling organizes order enquiry meeting. All required andrecommended changes pertaining to feasible production are discussed /finalized in the E-SamplingSamplingTeam & IEIE-SamplingConstructionChangesReport888

Proceedings of the International Conference on Industrial Engineering and Operations ManagementRabat, Morocco, April 11-13, 2017891011121314151617IE-Sampling fills the order enquiry sheet with details and sends the same viae-mail to respective merchandiser cc to GM-Production, IE Head, SamplingHead and Quality Manager.Total Lead Time to send the report is 2 working days.Merchandiser receives the Order Enquiry Sheet and prepares his order costsheet. Merchandiser then sends the order cost sheet to Buyer.Buyer receives order costs sheet and reviews the same, as per his ndiserMerchandiserBuyerOnce buyer approves the cost sheet, merchandiser confirms the order toGM-Production, IE Head, sampling head and quality head.Sampling prepares samples (Fit, Sealer, PP etc.). The samples are sent tomerchandiser and he forwards the same to buyer for approval.MerchandiserBuyer reviews the samples and recommends the required changes (if any).MerchandiserSamplingTeamIE-Sampling incorporates the changes in operation bulletin as per changesrecommended by buyer at every pre-production stage and generates FinalOperation Bulletin.Quality team organizes the Pre-Production Meeting. Production Team,Industrial Engineering Team, Quality Team & Maintenance Team attendthe meeting in order to discuss the Production details related to the style.Sampling team maintains Daily Production Report and Style Status Report.IE-SamplingDailyProductionReport &Style StatusReportFactorySamplingTeam3.2 Fabric Store Standard Operating ProceduresStore functions starts through supplier and goes through fabric inhouse, shrinkage and shedchecking and finishes through finally stored in warehouse for production as shown in rder Enquiry SheetFailsPassSupplierFabric In HouseCheck Containeris Sealed or NotUnloadingPhysicalChecking10% Sample PickedFabric Moved toInspection AreaShrinkage Exercisefor 100% RollsShed Blanket for100% RollsRandom RollsCheck for Length &WidthFabricInspectionShrinkageReportFails4 PointInspectionPassNext 20% 4 PointInspectionPassFailsNext 50% 4 PointInspectionShade bandReportFailsPassMerchandiserMarking onRollsStored in Racks& Issued toCuttingInventoryStatusReportBin Cardfor RacksFigure 2: Fabric Store SOPThe responsibilities of different designated persons has been explain ed in Table 2 which requires many decisionsregarding quality control department and sometimes from buyers also.889

Proceedings of the International Conference on Industrial Engineering and Operations ManagementRabat, Morocco, April 11-13, 2017Table 2: Responsibilities of Different Persons according to upplier receives order from purchase department on challan & the same issupplied by him with packing list & material challan for reference.2 Fabric is received in In-house by Store In-charge.Store In-charge checks whether the container is sealed/not sealed as per thechallan.If any issues are found, the details are advised to merchandiser and the respectivesupplier.If container is sealed, store in-charge guides unloading helpers to unload materialWhile unloading, rolls are counted & physically checked if there is any deviationfrom what is mentioned in challan.Random rolls are picked and checked for length and width by Fabric QC. Rollsare marked as per their length and width.Cut and prepare a continuity card from 100% rolls of fabric (Prepare a shadeblanket from 100% roll). Washing exercise is done and a shrinkage and shadeband report is prepared by Fabric QC.Once this is done, fabric is moved to Fabric Inspection Area.10% roll from the body fabric will be selected by Fabric QC.Roll number, color / lot no. (Reference from the shade card is entered in thefabric inspection form by Fabric QC.The rolls are then inspected as per 4-point grade system.If 10% inspection is passed, the inventory status report and bin cards for racksare updated and rolls are stored on racks to be issued to cutting department.If 10% inspection fails, another 20% of the rolls are randomly selected and put to4-point inspection test.If 20% inspection is passed, the inventory status report and bin cards for racksare updated and rolls are stored on racks to be issued to cutting department.If 20% inspection fails, 50% of the rolls are randomly selected and put to 4-pointinspection test. If 50% inspection is also fail, then the merchandiser & respectivesupplier is updated about the situation.ReportsSupplierStore In-chargeStore In-chargeStore In-chargeHelpersStore In-chargeFabric QCFabric QCHelpersFabric QCFabric QCFabric QCFabric QC &HelpersFabric QCFabric QCFabric QC,Store &Merchandiser3.3 Accessories Store Standard Operating ProceduresSimilar procedure applies for accessories store starting from supplier finishes through stored in warehouse forproduction through major decisions as shown in Figure FailsPassAccessories InHouseCheck Containeris Sealed or Not100% InspectionMetal ItemsPassStored in Racks& Issued toDepartmentsBin rtNon Metal ItemsUnloadingPhysicalCheckingTrims Moved toTrim InspectionAreaMetal Items areChecked for WeightRandomlyMerchandiserFails10% VisualInspectionPassFigure 3: Accessories Store SOP890

Proceedings of the International Conference on Industrial Engineering and Operations ManagementRabat, Morocco, April 11-13, 2017Table 3 shows the major responsibilities of responsible persons for storing at warehouse for production.Table 3: Responsibilities of Different Persons according to SOPSLNo.TasksResponsibility1Supplier receives order from purchase department on challan & the same issupplied by him with packing list & material challan for reference.Supplier2Fabric is received in In-house by Store In-charge.Store In-charge34567891011121314Store In-charge checks whether the container is sealed/not sealed as per thechallan.If any issues are found, the details are advised to merchandiser and therespective supplier.ReportsStore In-chargeStore In-chargeIf container is sealed, store in-charge guides unloading helpers to unloadWhile unloading stock, store in-charge counts & physically checks the stock ifthere is any deviation from what is mentioned in challan.Metal items are randomly selected & checked for weight confirmation.Trims are then moved to trims inspection area and put to inspection aftersegregating metal items from non-metal items.100% of Metal items are then passed through metal detector machine and trimsinspection report is updated accordinglyIf stock passes this test, the inventory status report and bin cards for racks areupdated and trims are stored on racks, to be issued to departments.If this stock fails, it is returned back to supplier and the same is informed toMerchandiser via email with cc to all department heads.10% of non-metal items are then visually inspected & trims inspection report isupdated accordinglyIf stock passes this test, the inventory status report and bin cards for racks areupdated and trims are stored on racks, to be issued to departments.If this stock fails, it is returned back to supplier and the same is informed toMerchandiser with cc to GM-Production, Quality Manager, IE Head.HelpersStore In-chargeStore In-chargeAccessories QCAccessories QCTrimsIRAccessories QCAccessories QCAccessories QCAccessories QCAccessories QC3.4 Cutting Section Standard Operating ProceduresThe cutting section functions starts from cut plan preparation and finishes through cutting, numbering, bundling andhandover to sewing section as shown in Figure 4.Order SummarySheetInseam & Size WiseOrder Summary SheetMacro Planningby GMPDaily Planning byCutting In-ChargeLayer ControlRoomBundleAssortmentStored inTrolleys forSewing SectionCutting OBPreparatoinSpreading TableStatus rationFailsPassMarker CheckSupervisors Gets theMarker from CADSupervisors Gets theFabric Issued fromStoreNumbering &Bundle CardGenerationNumbering ofPiecesPre Bundling ofLay Cut100% PartsChecking forQuality &NumberingCut Inspectionbased on AQLCuttingSAM BankCuttingOBCutting PlanPreparationSpreaders LaysFabric as perRatio &Quantity to CutOnline SpreadingInspectionMarkerPlacementCut PlanReport100% PanelChecking for BigPartsFusing ofSmall PartsShade Marking& Bundling ofPiecesFailsIE ActivitiesFigure 4: Cutting Section SOP891

Proceedings of the International Conference on Industrial Engineering and Operations ManagementRabat, Morocco, April 11-13, 2017Cutting section plays the first and main role for quality control and production. The major responsibilit ies has shownin Table 4.Table 4: Responsibilities of Different Persons according to SOPSLTasksResponsibilityReportsNoGM-Production prepares the macro plan of order seam&Size-wiseOrderSummary.2Cutting In-Charge34567Cutting In-charge prepares a Cut Plan in order to streamline theprocess of cutting and fabric utilization.IE-Cutting prepares the Cutting-OB which contains cuttingoperations, manpower and machines requirements.AutoCAD Operator prepares marker as per Inseam & Size-wiseOrder Summary Sheet. He also calculates marker efficiency andgenerates a marker efficiency report.Cutting supervisor gets the fabric issued from store as per cut planCutting Supervisor receives the marker form CAD department andchecks the marker for the number of parts and sizes as per cutplan.Cutting In-ChargeIE-CuttingOB, SMV BankAutoCAD OperatorMarker EfficiencyReportCutting SupervisorCutting SupervisorIf marker check fails marker is sent back to AutoCAD Operator tomodify and incorporate the recommended changes.If marker is OK, spreader lays the fabric as per marker length to becut and also fills layer control form.Cutting Supervisor10Spreader manually performs on the job spreading inspection onthe lays to check fabric defects like shade variation or major holes.Spreader11Spreader fills the start time, end time & type of activity in theSpreading Table Status Report located at each table.Cutting In-Charge12Cutter cuts the lay as per the marker and fills daily cuttingproduction report which highlights the actual status of cutting.IE-Cutting prepares the fabric utilization report to calculate thewastages in cutting.Helpers start pre-bundling of lay cut as per cut no and stores in theracks.Cutting ManCutting In-charge allocates the bundle number as per style, sizes,shades etc. and generates a bundle cardCutting In-Charge8913141516171819202122The cut parts are numbered by the numbering operators.Bundling operators perform shade marking and bundle the piecesaccordingly.Fusing is done for small parts like collar, cuff etc. using fusingmachine by fusing machine operators.100% panel checking for big parts and 100% parts checking forfabric quality, numbering & shade are performed by qualityinspectors.Quality Auditor performs inspection for cuts using AQL 1.5method of sampling.Bundled Cut parts are stored in trolley, ready to input for thesewing departmentIE-Cutting prepares Daily Efficiency Report for cutting.SpreaderIE-CuttingSpreading TableStatus ReportFabric UtilizationHelpersNumberingOperatorsBundling OperatorsDailyNumbering/BundlingFusing M/COperatorsQC In-chargeQuality AuditorCutting Prod.HelpersIE-CuttingCutting Eff.892

Proceedings of the International Conference on Industrial Engineering and Operations ManagementRabat, Morocco, April 11-13, 20173.5 Sewing Section Standard Operating ProceduresSewing section functions starts from line plan receiving and finishes at hand over to washing or finishing as shownin Figure 5.OrderSummarySheetLinePlanLine PlanReceived fromPlanningFinal OBValidation of InitialOB Prepared by IESamplingCalculation FinalManpower & M/CRequirementBundles Input atFront, Back,CPU SectionsStart of ProductionEfficiencyReportLine Balancing stSAM BankInput Man CollectsTrims & Accessoriesas per ChallanHourly ProductionMonitoring at everyW/SOperator CapacityCalculationLine LayoutFolders, Attachments& Work AidRequirementHourly ProductionReportSkill MatrixWork AidsListPreparation ofLine LayoutCopy of ChallanSent to StoreOff-StandardTime ReportInlineInspection7 PointSystemDaily Off-StandardTime CalculationFailSewing ReconciliationReportSewingReconciliationReportCut Parts Movedto Sewing fromCuttingDeliveryChallanInline &End lineDHUFailOutput pcs Delivered toProduction Accounting(Physical Counting)Pcs sent toWashingPassIE ActivitiesPassEnd lineInspection(100%)Figure 5: Sewing Section SOPThe responsibilities of different section incharge has shown in Table 5.Table 5: Responsibilities of Different Persons according to SOPSLNo.123456789101112TasksSewing department receives line plan from planning department.IE-Sewing validates Initial Operation Bulletin prepared by IESampling.IE-Sewing calculates final requirement of manpower andmachinery using the basis final operation bulletin.IE-Sewing advises the folders, attachments and work-aidsrequirements and gets it prepared.IE-Sewing also prepares a line layout for optimal utilization ofspace and resourcesCut parts are moved to sewing area using a trolley by an Inputman (loader).A copy of input challan is sent to store.Store in-charge issues the trims and accessories as per the challanto the input man.Batch Setting is being performed by the IE-Sewing, ProductionManager, Quality manager & Maintenance Manager. All themachines are set as per required quality.Bundles are then input at each section (front & back) as per thelayout defined by IE-Sewing.Start of production.Sewing Line is being balanced by Sewing-IE on the basis ofoperator capacity and target of the lineResponsibilityReportsPlanning In-chargeSewing - IEFinal OB,SAMSewing - IESewing - IESewing - IELoaderLoaderStore In-chargeSewing TeamLoaderIE-Sewing893

Proceedings of the International Conference on Industrial Engineering and Operations ManagementRabat, Morocco, April 11-13, 201713141516171819202122IE-Sewing calculates capacity of each operator to maintainoperator-wise performance.The pieces move in the lines on the center table in the form ofbundles till the last operation i.e. End line Quality Inspection.Supervisor monitors every workstation every hour to ensuresmooth movement of bundles in sewing line and fills the hourlyproduction sheet.Supervisor monitors off-standard activities at each workstationand fills the off-standard time report at each workstation. IESewing monitors the off-standard time of every line and takesnecessary action to reduce the same.Line QC performs quality check during sewing using Inline 7point system.If any wrong piece is found, the piece is being corrected and thenthe bundle is moved ahead in line. If the bundle is passed, then thebundle is moved ahead in the sewing lines.Once bundle passes end-line inspection, output pieces aredelivered to production accounts where pieces are countedmanually.Once counting of pieces is complete, pieces are sent to washingdepartment bundle-wise for washing of the pieces and a deliverychallan is issued against the same.IE-Sewing prepares daily sewing efficiency report.At the end of every style, Production Manager prepares SewingReconciliation Report.IE-SewingLine SupervisorIE-SewingOff-StandardReportLine QCLine QCProduction AccountsProduction AccountsIE-SewingEff. ReportProduction Manager3.6 Finishing & Packing Section Standard Operating ProceduresOrderSummaryFinishingLine PlanLine PlanWashingChallanWashed pcsReceived fromWashingFinishing OBPreparationShade GroupingReportShade Checking& SortingHourly ProductionReportLoop CuttingFinishing OB& SAM e DHUReportOutsidePressingInsidePressingFinal tionReportFinal Audit &ShipmentFinal tsideThreadCuttingRepair & RejectionReportMeasurementReportIE ActivitiesInside tPre-shipmentAuditPrice Ticket & JokerTicket AttachInline CartoonAudit ReportInlineCartoonAuditShade WiseSegregationNeedle DetectionM/C LogCartoonPackingSize WiseSegregationFigure 6: Finishing & Packing Section SOP894

Proceedings of the International Conference on Industrial Engineering and Operations ManagementRabat, Morocco, April 11-13, 2017Table 6: Responsibilities of Different Persons according to g Manager101112Order summary sheet is received from GM Production.Finishing Line Plan is prepared by Finishing Manager.IE-Finishing prepares Operation Bulletin depending upon the ordersize & quantity.Pieces are received by finishing department from washing as perwashing challan.Shade Segregation Operator segregates the washed pieces as pershade and Initial Shade Sorting is performed.Loops are being cut and hourly production report is being maintainedby Supervisor.Inside Thread Cutting, Checking, Outside Thread Cutting &CheckingSnap, Button or Fastener AttachPieces are then blown through the Thread Sucking Machine toremove all unwanted loose threads from the piece.Inside pressingOutside pressingFinal checking13Measurement Check for Key Points I.e. Out seam, Inseam & Waist.QI1415Final Presentation CheckPrice ticket and joker tag attachPieces are passed through Needle Detector Machine to Needle FreeZone for packing.Shade-wise and size-wise segregation of pieces as per requirementsThe product is then packed into cartons PO-wise and stored in cartonwarehouse.Inline carton audit is performed by Finishing Quality Auditor.Once the style is shipped, Finishing Manager prepares FinishingReconciliation Report.Quality tsOBProductionAccountsFinishing OperatorsTrimmersTrimmers & gatorsCarton PackersQuality AuditorFinishing ManagerReconciliationReportIt has been observed fro m the findings that the Industrial Engineering & Operat ions Management Functions are verycrucial for the success of the organizations. Without implementation of these functions in apparel manufacturingindustries it’s impossible to sustain in respect of costings, on time shipments and especially final customersatisfactions. Countries which are still in developing stage, need to start working on these functions.There are lot of consultants or consultancy firms are working on the implementations of Industrial Engineering andOperations Management Functions and the industries who are accepting these as necessity are highly succes sful inthe business. Moreover, Universities, Technical Institutes, Training Centers, Colleges, Schools are teaching thesesubjects in their course materials. It would be very helpful if consultants can be appointed for imp lementation of thefunctions then faster and successful imp lementation could be done and existing emp loyees could be trained formaintaining their responsibilities.3.6 Finishing & Packing Section Standard Operating Procedures895

Proceedings of the International Conference on Industrial Engineering and Operations ManagementRabat, Morocco, April 11-13, 20173.7 Style Changeover Standard Operating ProceduresLine Plan4 DaysAdvanceOB PreparatonMachine Layout3 equiredWork aidsRequiredCheck M/CAvailabilityArrange Folders/AttachmentsAvailable?Identify CriticalOperationsYesOperatorAllocation PlanAvailable?YesIn HouseCheck TrimsStatusYesIn HouseNoNo2 DaysAdvanceCheck FabricStatusNoYesNoArrange fromother Line/HireMake aidsRequiredMock SamplePreparationUpdate GM Production/IE ManagerPP MeetingMachine Setting1 DaysAdvanceQualityNoStart CuttingYesMachine ReadyCut Parts Input toLineTrims IssuedStyle InputLine Setting & Startof Bulk ProductionFigure 6: Style Changeover SOP4. Future RecommendationThe Industrial Engineering and Operat ions Management Functions was analyzed and successfully imp lemented atsome major sections of apparel manufacturing industry including sampling & preproduction, cutting, sewing,fin ishing & packing and finally changeover areas. For future study, several other sections could be included forimplementation. For examp le, maintenance section purpose Total Productive Maintenance (TPM) could beimplemented so that machine id le t ime & setting time could be reduced, some standard parameters based on similartype of styles could be set and made visible to all concerned persons so that for future production of similar stylesthe difficult ies faced could be identified and solved in advance. A mong so many fo lders, attach ments and work aidsa machine tools storing system could be developed so that faster arrangements could be done.Since, the analysis was done for sections, the analysis

Sheet 9 Total Lead Time to send the report is 2 working days. Merchandiser 10 Merchandiser receives the Order Enquiry Sheet and prepares his order cost sheet. Merchandiser then sends the order cost sheet to Buyer. Merchandiser 11 Buyer receives order costs sheet and reviews the same, as per his defined criteria. Buyer

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