Standard operating procedure of Industrial Engineer

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STANDARD OPERATION PROCEDURES (S.O.P.) FOR IE
I.E – SOP’s (Basic)
Style inquiry and development
1. Submit Estimated SMV, Outputs and efficiency levels for pre-costing.
2. Analyze and comment on potential of doing the orders inquired.
3. Attend for the product development meeting and provide proactive input
4. Attend to do the mock ups for approvals on required construction changes with the
evaluation of saving and benefits.
5. Calculate and submit thread consumption to the merchandising
Planning
6. Submit Estimated SMV, Outputs and efficiency levels for Production planning
7. Provide proactive input for efficient production scheduling
8. Check and approve production schedules for best options
9. Make production plan summaries
Pre-production
10. Testing and preparation for the confirmed orders – Methods, attachments
11. Revive the samples to submit and comments after receive
12. Prepare Operation bulleting and SMV.
13. Issue and discuss operation bulleting with Production and technical staff on processes and
process sequence before doing line sample
14. Attend for line sample with the production and quality staff
15. Get the confirmation on operation bulleting by the production staff before preparing line
layout
16. Prepare line layouts and discuss and confirm with production and technical staff
17. Prepare manpower allocation for layouts in advanced to the line feeding
18. Prepare skill inventory and skill requirement for each style
19. Prepare and attend on skill development for style based critical operations (Training in
advanced)
20. Maintain worker skill inventory
21. Prepare and attend on general skill development plan
22. Prepare fresher training manual
23. Supervise fresher training and training center activities
24. Prepare machine, attachment and manpower requirements based on latest production
schedules

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25. Make and follow line feeding plan
26. Follow up and make sure to available required machines, attachments and manpower on
time as style feeding plan.
Line feeding/New style introduction
27. Attend in new style introduction
28. Instruct and train workers on correct methods as motion sequins include in desired SMV
29. Arrange for best work place arrangements as method desired on SMV with maintaining a
style check list.
30. Explain the SMV, Targets and plan efficiency and Incentive levels to each and every
worker
31. Play an active role on reducing line feeding losses
32. Maintained line feeding report
33. Attend for style first bundle meeting
At Running Production and day to day
34. Capacity study of all Operations at two to three days after feeding
35. SMV revision and confirmation with comparing the capacity after complete the capacity
study
36. Make potential plans after capacity study
37. 1st line layout re-balancing based on actual capacities and as per potential plan
38. Attend in daily line pocket meeting
39. Attend on daily line balancing
40. Find the bottle necks, technical and quality issues and attend to solve with addressing to
the responsible persons
41. Interval capacity study and line layout re-balancing once a every two weeks’ time in first
month and once a month after first month
42. Plan and attend in Continuous Training of workers
43. Attend in Continuous method improvements and SMV reductions
44. Organize and conduct daily efficiency meeting with production staff
45. Improving individual efficiencies with monitoring and making sure that the efficiency
reports are accurate
46. Monitor and record individual and line off standard times and take necessary actions to
reduce the lost times. Address and discuss with management on off standard times
47. Achieve the maximum potentials of individuals and sections and maintain the minimum
capacity gaps
48. Achieved planed production targets and line efficiency

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Post Production
49. Style reconciliation of technical (SMV, Efficiency, Production output, Thread
consumption, Production plan, Bottlenecks)
50. Monitor the style reconciliation of received to ship
51. Monitor the post costing
General
52. Performance evaluation of workers and factory staff. Do the grading
53. Introducing and monitoring incentive schemes/Motivation tools
54. Plan and monitor the skill upgrade program
55. Management update on latest management concepts, Technology, systems and
procedures, methods, tools and attachments.
56. Maintain and achieve the targets of key productivity indicators and do the comparison
with other industries for management information
57. Maintain all filing and document systems
58. Special tasks/Projects assign by management
59. Attend for management meeting and give proactive input
60. Self training and maintain records of achievement
Industrial Engineer Job Description
Major Responsibilities
 Analyzing efficiencies of different sections/departments and identifying alternatives to
maximize the efficiency and reduce the cost.
 Make the Team aware to keep records on every work they do related to work study
functions.
 Ensure that the Management Reports are sent daily to the top management.
 Daily Factory Efficiency Report (Cutting Dept. Sewing and Finishing)
 WIP of Cutting, Sewing and Finishing Departments.
 Line Capacity Graphs.
 Off Standard Time Reports.
 Collect the reports prepared by IE persons, analyze and identify the most pressing needs
of the production process.
 Make regular visits to areas that directly relates to Production Cost and prepare plans to
reduce, if anything seems to contribute to increase the Cost per Minute of the factory.
 Make sure that the Industrial Engineers do Capacity Studies for the production lines and
Production Studies for individual operators. A Capacity study should be done once in
every two days until the line reaches the required efficiency level.

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 train the Work Study Engineers to see things in a wider perspective rather than seeing in
a narrow viewpoint.
 Regularly follow up the Functions of the Industrial Engineering Department to see
whether they are pening as per the schedule.
Job Related & General Responsibilities
 Areas for Improvement are related to material handling; shortening the process, reduction
of the operation time (SMV), costs, and simplification of the process, technology and
methods.
 Methodology
 Highlight every problem found, reported or heard during meeting.
 Evaluate the reasons and causes of the problem.
 Analyze the possible solutions to solve the problem.
 Compare alternative solutions to the problem.
 Introduce the most feasible, practical, effective, efficient and economical solution to the
system.
 Keep the detail of the solutions in a Project Tasks Inventory the way it is done, how,
when and by whom.
 Coach people and monitor the changes till they reach the total achievement.
Realizing and achieving the financial objectives of the entire group
Industrial Engineer should monitor the results achieved in the form of direct labor vis-à-vis the
objectives laid down in the Costing Formula
Methodology
 Determine the corporate objectives from the costing formula in relation to the number of
direct labor, absenteeism, minutes earned, production delays, and quality.
 Assure the results are achieved daily, weekly and monthly, in case of negative results.
 Find out the reasons behind each negative result.
 Evaluate a solution.
 Prepare an action plan.
 Implement the new changes or improvement.
 Report daily the results versus the action plan to the management.
 The cost of Cutting and Making should be realized against the price objectives in the
marketplace.
 Keep always these questions in mind while doing the costing:

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 Analyze all the operations seen in the sample at the first step.
 Try to simplify some of the operations in order to do them simultaneously,
 Get the Involvement of the equipment technologist for any trial of new idea or
development of new tool.
 Remember the piece handling and how to distribute them to the next operation.
 Eliminate any manual work by improving the work method of the sewing operation
avoiding reduction in the needle time.
 Propose any changes to the product development for approval.
 Try any new ideas before implementation.
 Assure that all SMVs have the degree of confidence exceeding 95%.
 Assuring the functionality of the bundle system (Bundle Check List) among all areas
 Assure that the bundles system is respected through the manufacturing chain starting
from the cutting to the packing.
 Providing accurate data to the management for control and evaluation
 Assure that Operations Breakdown has control points over each area of production
control.
 Assure Bundle tickets are taken by the direct labor at each stage.
 Assure production delays are monitored and reported by the direct labor.
 Assure direct labor transferring to indirect is monitored.
 Analyze all production and efficiency reports before submitting to management and
correct if any found.
 Submit the reports daily to the management.
 Monitoring the direct labor earning and excess costs
 Regularly monitor that the direct labor on the production floor are working against SMV,
 Assure the utilization of the right equipment as it has been analyzed during costing,
 Assure, if the direct labor is not producing any minutes (SMV), to be considered as a
100% production delays.
 Analyze the production delays with their reasons.
 Come out with action plans to improve delays and turn them into production earnings.
 Use the captured data to analyze individual performance when ever they are not seen to
be performed accordingly.
 Make sure that the direct labor is applying to the same work-methods and workstation
set-up as described in the operations analysis.
 Eliminate any occasional elements and correct any deviation in work-methods by
observing the work elements logically.
 Ask for the assistance of the supervisor to show the operator the correct way of doing in
case of difficulty handling by the sewing machine operator.
 Do Time Studies for the operations that seem erroneous and confirm them by analyzing
against the MTM 2 values.
 Monitoring the Direct Labor Ratio per activity

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 Monitor employee’s structure versus the labor objectives ratio as described in the costing
formula to assure the earning performance in minutes as per the formula of the cost per
minute production.
 Providing economical methods and production line set ups for better line balancing and
feasibility
 Production Line set –ups should be analyzed in order to find the best number of
employees required for better line balancing and better efficiency without relying on the
output as objective.
 Industrial Engineer should run through very line set-up with the line balancing software
to analyze the line balancing efficiency and achievement and to highlight to the
supervisors where assistance and balancing is required in order to pull the production
chain.
 Monitoring the manufacturing processes and systems
The mandatory indications of work activities of IE/Work study Department.
Pre-production
 Proceed on through the production plan & collect new style sample of relevant
production lines.
 Prepare Operation bulletin with individual SMV(standard minute value) & discuss with
costing team grading confusion on SMV.
 Discuss with sample room IE/work study to clarify method of construction, attachments
& new machines.
 Discuss operation bulletin with Production and technical staff.
 Attend for line sample.
 Confirm operation bulletin.
 Prepare primary line layouts and discuss with production and technical staff, after the
discussion adjust the layout as agreed & confirm.
 Prepare skill requirement for each style.
 Prepare and attend on skill development programmers (Training in advanced- critical
operations)
 Maintain worker skill inventory.
 Prepare and attend on general skill development plan.
 Prepare machine, attachment and manpower requirements based on latest production
schedules.
 Make line feeding plan.
 Follow up and make sure to require machines, attachments and manpower is ready.

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Line feeding
 Attend in new style introduction.
 Feed the line as per the finalized layout & follow-up.
 Instruct and train workers on correct methods as motion sequence include in desired
SMV.
 Arrange for best work place arrangements as method desired on SMV.
 Explain the SMV, Targets and plan efficiency and Incentive levels to each and every
worker.
 Maintained line feeding plan.
 At Running Production and day to day
 Capacity study of all layout/Operations at two to three days after feeding.
 Find the bottle necks, technical and quality issues and attend to solve with addressing to
the responsible persons.
 SMV revision and confirmation with comparing the capacity after complete the capacity
study.
 Line layout re-balancing based on actual capacities and as per the plan.
 Attend in daily line pocket meeting.
 Attend on daily line balancing.
 Study the present method of work of sewing machinery operation & manual operations &
suggest improved method to achieve high efficiency level.
 Improving individual efficiencies with monitoring and making sure that the efficiency
reports are accurate.
 Monitor and record individual and line off standard times and take necessary actions to
reduce the lost times. Address and discuss with management on off standard times.
 Achieved planed line efficiencies.
 Post Production
 Prepare style review report with all the data, in order to avoid delays doing experiment in
repeat styles. (SMV, Efficiency plan & achieved, Production output, Thread
consumption, Technical issues, Bottlenecks).
General
 Performance evaluation of workers and factory staff.
 Introducing and monitoring incentive schemes/Motivation programmer.
 Management update on latest management concepts, Technology (Special machine),
systems and procedures, methods, tools and attachments.
 Special tasks/Projects assign by management
 Maintain records of achievements