20.
Most Used Formulas for Industrial Engineers in Garments and
Textile Industry
1. SAM (Standard Allowed Minute)
Formula: SAM = Basic Time × Performance Rating
Or,
Basic Time =Cycle Time × performance Rating [Basic Time = SMV]
Example:
SAM =
2. SMV (Standard Minute Value)
Formula: SMV = (Basic Time + Allowances)
Or,
SMV= (SAM-Allowance)
Example:
then SMV
3. Earned Minute
Formula: Earned Minute = (Total Production × SAM)
Example:
then Earned Minute =
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4. CPM (Cost Per Minute)
Formula: CPM = SMV × CPM
Example:
then CPM =
5. CM (Cost of Manufacturing)
Formula: CM = Total Cost / Total Produced Pieces
Example:
CM=
6. Daily Line Target
Formula: Daily Line Target
= (Total Working Minutes × Manpower × Line Efficiency) / SAM
Example,
Daily Line Target=
7. Individual Operator Target
Formula: Operator Target = (Total Minutes Available × Efficiency) / SAM
Example:
If an operator has 480 minutes, efficiency = 80%, SAM = 2.5 min,
then target = (480 × 0.8) / 2.5 = 153 pieces.
8. Line Efficiency
Formula: Efficiency = (Earned Minutes / Total Available Minutes) × 100
Example: If earned minutes = 3000 and available minutes = 4000,
efficiency = (3000/4000) × 100 = 75%.
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9. Individual Operator Efficiency
Formula: Efficiency = (Output × SMV/ Working Min × Man Power) × 100
Example
Efficiency =
10. Production Cost Per Unit
Formula: Cost Per Unit = Total Production Cost / Total Pieces Produced
Example: If total cost =
cost per unit =
11. Machine Productivity
Formula: Machine Productivity = Total Output / Total Machines Used
Example
productivity =
12. Labor Productivity
Formula: Labor Productivity = Total Output / Total Operators
Example: If 6000 pieces are produced by 100 operators,
productivity = 60 pieces/operator.
13. Machine Utilization (%)
Formula: Machine Utilization = (Actual Running Time / Total Available Time) ×
100 Example: If a machine runs 420 minutes out of 480,
utilization = (420/480) × 100 = 87.5%.
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14. Man to Machine Ratio (MMR)
Formula: MMR = Total Manpower / Total Machines
Example: If total manpower = 300 and machines = 150, then MMR = 2.
15. Monthly Factory Capacity
Formula: Monthly Capacity =
(Working Hour ×60 ×Total Worker × Working Days× Factory Efficiency)
Avg SMV
Example:
then capacity =
16. Cut to Ship Ratio
Formula: Cut to Ship Ratio = (Total Shipped Pieces / Total Cut Pieces) × 100
Example: If 9800 pieces are shipped out of 10000 cut pieces,
ratio = (9800/10000) × 100 = 98%.
17. Cut to Ship Loss
Formula: Cut to Ship Loss = (1 - Cut to Ship Ratio) × 100
Example: If cut to ship ratio = 98%, then loss = (1 - 0.98) × 100 = 2%.
18. Total Financial Saving
Formula: Saving = (Number of extra pieces shipped × Avg SMV)
Saving:
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19. DHU (Defect Per Hundred Units)
Formula: DHU = (Total Number of Defects found ×100) / Total Checked Pieces
Example: If 150 defects are found in 5000 pieces,
DHU = (150/5000) × 100 = 3%.
20. Pitch Time
Formula: Pitch Time = Garments SAM of Line / No. of operation
Example: If total SAM = 100 and operation = 20,
then pitch time = 5 minutes.
IE (INDUSTRIAL ENGINEERING) VIVA TIPS
IE INTERVIEW QUESTION CATAGORY
• General Question
• IE Narrative Question
• Calculative Question
• Factory Related Question
• Mind Mapping Questions
General Question
➢ Introduce yourself/Tell me about yourself.
• Your name/Father & Mother name
• Briefly about you family Education details
• Current position and some special achievement (if any)
➢ What do you do now in your job/ What is your job responsibilities?
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• The answer will be what you do. Tell everything by sequence. RAC
Sellen
IE Narrative Question
• Time study
• Method study
• Motion study
• SAM/AMV/NVA/NPT calculation
• Operation bulletin
• Line layout
• Line balancing
• Bottleneck identifying and removing
• NPT reducing
• Operator recruiting
• Overtime distribution
• Production follow-up etc.
Calculative Question
• SMV/SAM
• Target
• Cycle time
• Required number of operators
• Marker efficiency
• Basic Lime
• Observed time
• Rating
• Operator performance
• AQL
• Efficiency (Machine/Labor/Line/Floor/Factory Efficiency)
• Productivity (Machine/Labor/Line/Floor/Factory Efficiency)
• Capacity (Line/Floor/Factory Capacity)
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• MMR
• Throughput Time
• Produced Minutes
• Earned Minutes
• CPM
• What is 5S?
• What is 7/8 Wastes?
• CM
• Machine Utilization %
• DHU
• Defective Percentage
• Cut to Ship Ratio
• Cut to Ship Loss
• Pack to Ship Ratio
• On time Shipment %
• Pitch Time
Factory Related Question
• What is your factory average SMV, Efficiency, Productivity?
• What is your factory MMR?
• What is your factory revenue per month or year?
• How many workers do your factory have?
• How many lines do your factory have?
• How many machines do your factory have?
• What is the name of your factory's MD/DMD/Chairman?
• What is the group name of your factory?
• How many factories do your group have?
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Mind Mapping Questions
• What you want to leave your current factory?
• What is your current designation and what is your expected
designation?
• Why you think that you are suitable for this expected
designation?
• What is your current salary and what is your expected salary?
• Why you think that you are eligible for this expected salary?
• Why you think you are the best rather than all of other
candidates?
• What is your best achievement in your career life?
• Why we will hire you?
• If your selected when you can join?
Md. Sajal Ahmed
B.Sc. in Textile Engineering
Uttara University
Uttara, Dhaka.
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