a rough overview of industrial engineering in sewing department shivam.sagar.nift@gmail.com

1. Industrial Engineering in Garments
(IE in Sewing Department )
Database Management Apparel System
Assignment – 1
Name of Group Members:
1. Suraj Gangurde
2. Shivam Sagar

2. Index
1. Introduction
2. Roles of IE
3. Requirement analysis
4. Process Flow Diagram
5. Work Flow Diagram
6. Entity Relationship Diagram
7. Data Flow Diagram

3. Industrial Engineer :
Industrial engineering is a branch of engineering which is
related with the optimization of complex systems or processes.
It is totally concerned with the improvement, development, and
implementation of integrated systems of people, money,
information, knowledge, energy and it’s also analysis as well as
the mathematical, physical and social sciences together with
the principles and systems of engineering design to predict and
assess the results to be obtained from such types of systems.

4. Roles of IE:
1. Planning layouts
2. Monitoring Production flow system
3. Decide the machines and attachments for all style
4. Monitoring and improve the operator performance
5. Operator training
6. Production control system
7. Quality control
Requirement Analysis :
1. Time study
Time Study is the analysis of a specific job by a qualified worker in an effort to
find the most efficient method in terms of time and effort. Time Study measures
the time necessary for a job or task to be completed using the best method.
2. Method study

5. Method study the process of subjecting work to systematic, critical scrutiny to
make it more effective and/or more efficient. It is one of the keys to achieving
productivity improvement.
3. M/c Calculation
4. Skill Matrix
Effective tool to boost productivity in apparel Industry Training . Skill
matrix is a table that shows skills of individuals in a team and any gaps between
the skills of employees and the job roles they have.
5. Thread Consumption
Calulation and analysis of the requirement of thread.
6. Calculate SAM
Standard allowed minute (SAM) means how much time is required to make one
complete garment including allowances. SAM is used to measure the task or
work content of a garment. This term is widely used byindustrial engineers and
production people in the garment manufacturing industry.
7. Operation Breakdown
The method of preparing operations' list in a sequence is called as operation
breakdown.
8. Calculate Efficiency

6. Process Flow of industrial engineer :
Negotiation with Garment Merchandiser
Garment Analysis
Make P.P meetingif all the required fabrics , trimmings and accessories are in housed .
Production Target
Set machine layout

7. Line setting
Line Balancing
Continuous production meeting
Collecting production data
Preparing production report
Production report analysis
Report submit to factory Manage

8. Explanation:
01 Negotiation with garments merchandiser
It is the very first work of an industrial engineer. Here, he should vastly discussed with
garments merchandiser about the in-coming garments product.
02 Garments analysis
Confirmed garments product is clearly analyzed here by industrial engineer. It helps to
complete rest of the processes very easily.
03 Make P.P meeting
Here, P.P meeting should be organized if all the required fabrics, trimmings and
accessories .
04 Production target
Production target should set here according to factory capacity. It helps to respect the
shipment date.
05 Set machine layout
Machine layout is set here according to total processes needed to complete a
garment item.
06 Line setting
In this process, actual line setting should be done to utilize the garment workers
properly. If it takes more time in line setting then garments production will be
decreased.
07 Line balancing
To minimize the number of work stations, cycle time, line balancing is done here. Its
a very important process to achieve desired production target.
08 Continuous production meeting
Production meeting should be done here at regular interval. If any problem will arise
during garments production, should take necessary actions to solve that.
09 Collecting production data
Production data should be collected here for preparing production report.
10 Preparing production report
Here, total garments production report has prepared to analysis about the whole
production.
11 Production report analysis
Garments production report is analyzed here from different points of view.
12 Report submit to factory manager
Finally garments production report have to submit into the factory manager.

9. Work Flow :
CALCULATE SAM OF
GARMENT AND
DIFFERENT
CONSUMPTIONS
WORK
MEASUREMENT OF
NEW CONFIRMED
ORDER
TO ADVICE PRODUCTION
DEPARTMENT ON
GARMENT SAM AND LINE
LAYOUT
TO CALCULATE LINE
EFFICIENCY
DAY TO DAY
ACTIVITY
TO CALCULATE
OPERATOR
EFFECIENCY
GRADE CHANGE OF
OPERATORS
TIME AND METHOD
STUDY
TIME STUDY
CHECK FOR WORK AIDS
AND COMPLIANCES
PREPARATION OF
INCENTIVE SCHEME

10. Database Management Format:
A data management format helps in manage data, meet funder requirements, and help
others use data if shared.
Buyer:
 Buyer id (int, 5)
 Details (text ,15)
 Order No. (int, 9)
 Style No. (int ,5)
 Product Type (text, 15)
Order Details:
 Style No. (int ,5)
 Product Detail (text, 15)
 Quantity (int, 9)
 Size Ratio (int, 5)
Operation Bulletin:
 Operation no. (int, 3)
 Name (text ,15)
 Runtime (int, 9)
 Efficiency (int, 3)
 SAM (int ,10)
 Work Center (text, 15)
 Remarks (text, 15)
Thread Consumption:
 Style No. (int ,5)
 Size (text ,5)
 SPI (int ,1)
 Quantity (int, 10)
 Operation Description (text, 15)
 Machine Type (text ,10)
 Seam Length (int ,3)

11. Costing:
 Total thread consumption (int 3)
 Thread rate (int 3)
 Price mtr. (int 4)
Hourly Production:
 Style (int 5)
 Quantity (int 9)
 SAM (int 10)
 Pieces per shift (int 4)
 Total avl. Min (int 10)
 Pieces pr.hr. (int 5)
Sewing:
 Layout (text 10)
 Efficiency (int 3)

12. BUYER
ORDER
No.
BUYER
Id
DETAIL
S
STYLE
No.
MERCHANDISING
ORDER DETAILS
STYLE No.
PRODUCT
DETAILS
INDUSTRIAL
ENGINEETING
THREAD
CONSUMPTION
OPERATION BULLETIN
SAM
HOURLY
PRODUCTION
SEWING
Product
type
QUANTITY
SIZE
RATIO
TECH
PACK
STYLE
TOTAL
AVAILABLE
MIN.
QUANTITY
PIECES PER
HOUR
SAM
PRICE PER
SHIFT
SAM
OPERATION
No.
OPERATION
NAME
REMARK
RUNTIME
EFFICIENCY
WORK
CENTRE
SIZE
STYLE No.
SPI
OPERTION
DESCRIPTION
SEAM
LENGTH
QUALITY
MACHINE
TYPE
LAYOUT EFFICIENCY
Merchandiser
E-R Diagram
IE
SAM Operation
Bulletin
Thread
Consumption

13. BUYER MERCHANDISING
Industrial engineeer
(IE)
Production Report
Level-0 Data Flow Diagram
Order Details
Costing Details
Order
Production
Report
Merchandiser
Production
Details

14. BUYER MERCHANDISING ORDER DETAILS
THREADING
Industrial engineeer
(IE)
FEASIBILITY
OPERATION BULLETIN
HOURLY PRODUCTION
SEWING
Production Report
Level-1 Data Flow Diagram
Order
Requirement
analysis
Sending
Report
Thread
Consumption
Techpack
Procedure Starts
Order
procede
to
sewing
floor
Sending report
Production
Report
Thread
Consumption
Operation
Bulletin
Feasibility
Details

15. BUYER MERCHANDISING ORDER DETAILS COSTING
THREADING
PURCHASE SOURCING
Industrial engineeer
(IE)
FEASIBILITY
OPERATION BULLETIN
SAM
COSTING
HOURLY PRODUCTION
SEWING
Production Report
Level-2 Data Flow Diagram
Costing Details
Costing
Details
Requirement
analysis
Calculation
Sending
Report
Order
Thread
Consumption
Production
Report
Feasibility
Thread
Consumption
Operation
Bulletin
Details

16. BUYER MERCHANDISING ORDER DETAILS COSTING
THREADING
PURCHASE SOURCING
Industrial engineeer
(IE)
FEASIBILITY
OPERATION BULLETIN
SAM
COSTING
HOURLY PRODUCTION
SEWING
LINE PLAN
MANPOWER
REQUIREMENT
LINE BALANCING
MACHINE
REQUEST
LINE LAYOUT OPERATIVE CAPACITY
Production Report
Request Generation
Purchase of Thread
Orders
Level-3 Data Flow Diagram
Calculation
Costing Details
Production
Report
Thread
Consumption
Feasibility
Operation
Bulletin
Sending Report
Costing
Details
Order
Sending Report
Requirement
analysis
Details

19. Normalization:
Normalization is the process of reorganizing data in a database so that it meets two basic
requirements .There is no redundancy of data (all data is stored in only one place), and data
dependencies are logical (all related data items are stored together). Normalization is
important for many reasons, but chiefly because it allows databases to take up as little disk
space as possible, resulting in increased performance.
Buyer:
 Buyer id
 Style no.
 Product Type
Order Details:
 Style No.
 Product Detail
 Quantity
 Size Ratio
Operation Bulletin:
 Style No.
 Operation no.
 Runtime
 Efficiency
 SAM
Thread Consumption:
 Style No.
 Size
 SPI
 Quantity
 Seam Length
Costing:
 Thread rate

20.  Price mtr.
 Quantity
Hourly Production:
 Style no.
 Quantity
 SAM
 Pieces per shift
 Pieces pr.hr.
Sewing:
 Layout
 Efficiency