Industrial Engineering is System Efficiency Engineering. It is Machine Effort and Human Effort IE. 4 Million Page View Blog. 200,000+ visitors. (36,000+ pv, 25,500+ visitors in 2025.)------------------
Blog Provides Industrial Engineering Knowledge: Articles, Books, Case Studies, Course Pages and Materials, Lecture Notes, Project Reviews, Research Papers Study Materials, and Video Lectures. 2025 - New Project - Effective Industrial Engineering and Productivity Management.
Lean thinking is aligning the people and process to the purpose (customer value) so that the provider prospers. Going lean is not getting into cost reduction but to focus on getting more and more with less and less. Lean organisation searches for a perfect process that is valuable (value creating for the customer), Capable (minimise process variability), Available (reliable processes), Adequate (to meet the demand), flexible, flowed (moving towards one piece flow), pulled (provide when the customer wants) and levelled (anything any time).
Lean is not restricted only to large manufacturing organisations. It is applicable for service industry as well. It is applicable for SMEs also. Wherever there is a customer, there is customer value. Whenever customer value has to be fulfilled Lean is applicable. http://www.sfalignment.com/services/lean_management/ Savoirfaire Management Services Pvt. Ltd.
525/526, The Bombay Oil Seeds and Oils Exchange Premises Co-Operative Society,
Commodity Exchange Building,
Near Dana Bazaar,
Sector 19, Vashi,
Navi Mumbai 400705.
E-mail: sfalignment@gmail.com, sfgroup@vsnl.com, admin@sfccostmanagement.com
SewEasy Pvt. Ltd. based in Colombo, Sri Lanka specialize in implementing "modern work study systems" at apparel manufacturing factories around the globe. We are the Asia's number one provider for such PMTS systems since 1996. What’s unique about our industrial engineering approach is that, SewEasy system can be implemented within days to bind the production and quality teams together, to put forward their best efforts to increase efficiency. The value engineering benchmarks and Key Performance Indicators based on the SewEasy method, serve many factories across the continents.
SewEasy Pvt. Ltd. based in Colombo, Sri Lanka specialize in implementing "modern work study systems" at apparel manufacturing factories around the globe. We are the Asia's number one provider for such PMTS systems since 1996. What’s unique about our industrial engineering approach is that, SewEasy system can be implemented within days to bind the production and quality teams together, to put forward their best efforts to increase efficiency. The value engineering benchmarks and Key Performance Indicators based on the SewEasy method, serve many factories across the continents.
Production Method - Technology Efficiency Engineering
Mayur Shah, Mumbai
consultant specialising in plastics moulding, project planning and implementation, and water cooling optimisation. Email: kankuenterprises@hotmail.com
Important event for industrial engineers and productivity managers.
2025 India National Productivity Week - 12 - 18 February Theme - From Ideas to Impact: Protecting Intellectual Property for Competitive Startups.
The UK Department of Trade and Industry’s (DTI 1998) definition of innovation,
‘the successful exploitation of new ideas’.
The theme for Productivity Week 2025 provides a crucial platform to address the interconnected challenges and opportunities related to innovation, intellectual property (IP), and productivity within the Indian startup ecosystem.
For industrial engineers innovation and productivity are important themes to focus on. IEs have to organize events, participate in the event actively and promote industrial engineering as the department, function and discipline to promote productivity through innovation.
I am collecting background material to support industrial engineers in preparing for the events of the week.
Background Material
2025 India National Productivity Week - February 12- 18, Theme - From Ideas to Impact: Protecting Intellectual Property for Competitive Startups.
The Industrial Engineering discipline has been fostered and developed In our country by the Professional Institution, the Indian Institution of Industrial Engineering, founded as early as 1957. During the last five decades and more, the Institution has been consistently doing extensive and pioneering work in disseminating, fostering, developing and advancing the discipline and profession of Industrial Engineering in our country.
"Industrial Engineering is concerned with the design, improvement and installation of integrated systems of men. materials and equipments. It draws upon specialized knowledge and skill in the Mathematical, Physical and Social Sciences together with the principles and methods of engineering analysis and design to specify, predict and evaluate the results to be obtained from such systems".
Some of the VITAL areas regularly covered by Industrial Engineering are :
Strategic Planning
Strategic Planning for Industrial Engineering
R&D Management; Technological, Economical and Market Forecasts; Investment Analysis; Location, Manufacturing Strategies; Product/ Service Mix and Range; Global Trend etc.
Product / Service Design
Product Industrial Engineering
Innovation; Customer Needs, Value Analysis; Product Quality and Reliability ; Process Design, Standardisation; Obsolescence, Upgradation, Replacement; World Standards etc.
Work System Design
Work System Industrial Engineering
Operations Analysis, Plant Layout and Material Handling; Flexible Manufacturing. Automation; Capacities Financing and Financial Controls; Operations Design, Main Considerations; Productive Maintenance, Total Quality Management, Cost and Budgetary Controls, Employee Training etc. Standards, Bench Marking, Business Process Re-engineering, Modernisation, Global Developments etc.
Supply Chain Management
Supply Chain Industrial Engineering
Materials Management, Frame work to analyse Supply Chains, Transportation in a supply chain, Facility Decisions-network in a supply chain and Information Technology in a supply chain.
Human Resource Management
Human Effort Industrial Engineering
Skill Analysis, Forecasting and Man Power Planning; Training and Retraining, Employee Motivation and Retention; Redeployment, Appraisal, Counselling, Personal Development; Environment of Knowledge Based Work, Knowledge, Workers etc.
Cashing On Communication And Information Technology
Quantitative Analysis; Information Systems; Networking between Locations, Vendors and Customers; Computer-assisted Planning and Control of Operations, Materials etc. Computer assisted Accounting, Budgetary and Costing System; Computer Aided Designing, Computer Aided Manufacturing, Expert Systems etc.
Other Areas
Involving Systems with Technical, Economic and Social Considerations and their Interfaces.
Online Education/Training Session on "Effective Industrial Engineering and Productivity Management."
I developed an online education/training session on "Effective Industrial Engineering and Productivity Management." I can present the session in one hour, one and half hour or two-hour long sessions. The sessions will be valuable when company industrial engineers and other engineers and managers attend as a group. Industrial engineers require active cooperation and participation of other engineers and managers in their studies and projects. Hence a common presentation and discussion on effectiveness will be very useful.
Supporting Information.
Effective Industrial Engineering - Some Thoughts by Narayana Rao K.V.S.S.
Effective industrial engineering has to satisfy management about the contribution it made to the organization year after year.
The prime contribution of IE has to be cost reduction through productivity improvement.
The primary focus of IEs has to be improvement of engineering. In addition to it, they have to improve many other areas. In all areas including engineering, they have to involve specialists from those areas to do detailed designs, production and installation. Industrial engineers have to evaluate all new developments in engineering for use within the systems, facilities and processes in their organization for productivity improvement.
Modern Industrial Engineering - A Book of Online Readings.
365+ Lessons and articles and 100+ Case Studies on Industrial Engineering.
My contribution to the article in the section Process Integration
Integrating AI into existing processes.
Applied Industrial Engineering is doing industrial engineering with new technologies and doing industrial engineering in new technologies. The emergence Deepseek from China is an example of doing IE in artificial intelligence technology. Cost reduction of a product in AI technology was achieved. Improving processes is the responsibility of industrial engineers and they have to use AI in the processes wherever it is applicable and economical. They have to evaluate various elements of AI technology and various AI products available in the markets for potential productivity benefits. They have to ascertain the price and internal cost of implementing that solution or product. Companies in which IEs use AI will have competitive advantage.
AI tools to boost productivity
AI tools are designed to streamline workflow and improve efficiency.
Leveraging AI to Enhance Productivity and Customer Experience in the Hospitality Sector
Asian Productivity Organization
Premiered on 14 Nov 2024
As AI reshapes industries, its role in hospitality stands out for its ability to personalize experiences, streamline operations, and boost overall efficiency. This talk explores how AI can support the hospitality sector in meeting evolving guest expectations where personalized, responsive, high-quality experiences are no longer a luxury but an expectation. It also delves into the multifaceted ways AI can improve customer loyalty, operational productivity, and dynamic service through data-driven insights and automation.
Dr. Sara Quach Thaichon, Senior Lecturer in the Department of Marketing, Griffith University, Australia, discusses how investment in quality AI solutions can help firms in the hospitality sector to navigate this technological transformation with agility, fostering guest satisfaction and loyalty in an increasingly competitive landscape.
Though job profile of an Industrial Engineer may vary from one company to another, most of the job profile fall under following list.
1. Knowledge about various sewing production systems
2. Knowledge of all types of Sewing machine necessary for the company
3. Time study (Cycle timing)
4. Motion analysis of the operations
5. Operation break down
6. Preparation of OB (Operation bulletin)
7. SAM Calculation
8. M/C Layout and Work station layout
9. Line Set up
10. Production estimation of a line
11. Work Sampling
12. Method Study (Seeing Movements of an operation)
13. WIP Control
14. Line Balancing
15. Capacity study
16. Cost estimation of a garment
17. Developing and Maintaining Skill Matrix
18. Incentives schemes
19. Calculating Thread Consumption
20. Work aids, Guide and Attachment
21. Performance Rating
An industrial engineer must have knowledge and skill on each tool and technique. Implementation of all tools at a time is not needed. An engineer has to go step by step.
Almost all work-study tools and methodology are adopted from others industries and implemented in the garment industry. So each work-study tool has guaranteed benefit if it is used effectively.
My comment on the above LinkedIn Post: "Knowledge of all types of Sewing machine necessary for the company" Machine effort industrial engineering has to be the primary task.
Machine Work Study in Garment Manufacturing Factories
Analysis and Evaluation of Potential Benefits to Process Productivity Improvement
Industrial engineers have to evaluate every engineering and technology development in textile and garment engineering for its potential benefit to the systems and processes in their organization
2025
Automatic Pocket Making Machine by Dazza Automation Technology
Using Automation in Design to Unlock Time | Clothing Tech | PI Apparel
PI Apparel
William Wilcox, Founder and CEO of Clothing Tech, shares how the Garment Digital Twin is revolutionizing fashion design. This cutting-edge 3D CAD solution boosts efficiency, reduces waste, and enables precise digital replicas, setting the stage for a more sustainable industry.
IMPROVING PRODUCTIVITY OF APPAREL MANUFACTURING
SYSTEM USING VALUE STREAM MAPPING AND PRODUCTION
CONTROL TOOLS FOCUSING ON PRINTING SECTION
Md. Ahasan Habib, , A.M.M. Nazmul Ahsan and , Md. Bony Amin
Department of Industrial Engineering and Management, Khulna University of Engineering & Technology,
Khulna-9203, Bangladesh http://ijret.org/Volumes/V02/I09/IJRET_110209091.pdf
Managing Productivity in Apparel Industry
This is probably the only book solely dedicated to productivity improvement in the apparel industry. Through his extensive research, Prof. Rajesh Bheda has established that the average apparel manufacturer in India and a large part of the developing world have almost one hundred per cent productivity improvement potential.
Author:
Dr. Rajesh Bheda
Book Price:
$35 Rs.345 http://www.apparelresources.com/book3.asp
Rajesh Bheda, A.S. Narag, M.L. Singla, (2003) "Apparel manufacturing: a strategy for productivity improvement", Journal of Fashion Marketing and Management, Vol. 7 Iss: 1, pp.12 - 22 http://www.emeraldinsight.com/journals.htm?articleid=858534
Many links may have to be removed as Blogger made the remark that some malware or virus is there in this blog post. How to locate and remove the malaware and virus. Does blogger has any feature that scans blog posts?
Why Machine Work Study?
Improvement Possibilities - "Replacement of Machines Opportunity" to "Work Aids Provision" and "Incremental Machine Level Automation"
Automatic machines are now available for replacing currently used machines. Do replacement analysis. Replacement analysis is industrial engineering. It is specially taught in IE Engineering Analysis.
Highlighted case study
Improving Productivity by Using Extra Mechanical Automation on Different Sewing Machine. Interesting case study.
One machine was changed. Automation increased on some machine. Due to these machine related changes, manpower was reduced from 70 to 62 in this line.
"Sweater production process" has many results in google search.
Difference between Single Jersey and Interlock Circular Knitting Machine
30/05/2022 by textileblog
Single Jersey Circular Knitting Machine:
Single jersey circular knitting machine is the most used knitting machine in textile knitting industry. Latch needle, cylinder and sinker ring revolve through the stationary knitting cam systems
Interlock Circular Knitting Machine:
Interlock circular knitting machine is also a very commonly used machine in country to make interlock knitted fabric. The machine has two sets of needles on two different beds, one set on cylinder one in the dial bed
In this study, the KITECH logo was designed over the sports bra pattern using technical embroidery techniques. embroidery techniques. For this, a technical embroidery machine (SGVA 0109-825, ZSK Stickmaschinen, Krefeld, Germany) was used.
Automatic cutting machines can cut single or multiple plies of a wide variety of fabrics, from lightweight apparel fabric to high-performance industrial fabrics. Cutting can be performed using a laser, knife, or water-jet. The advantages of automatic cutting are the increased efficiency and accuracy, ease of cutting single and multiple plies, and perfect cutting the first time.
In this study, several embroidered fabrics were placed on the automatic cutting machine (P-CAM 161, Shima Seiki, Wakayama, Japan) for cutting into the patterns. For matching the embroidered logo on the accurate position, a full-size pattern piece was projected on the fabric as it was spread over the cutting surface using an overhead projector.
Robot Handling with a Gripping System
As a result, an electric needle gripper (SNGi-AE, Schmalz, Glatten, Germany), which can electrically adjust the length of the edle stroke, was chosen for this study; It showed robust performance for numerous fabric types without noticeable damage.
Automatic Sewing
In this study, two tasks were performed to realize automatic sewing technology. First, an automatic feeding system was developed to develop an automatic sewing process using a motor and acceleration sensor. The automatic feeding system was located on the right side of the industrial pattern sewing machine (ASM-224, JUKI, Tokyo, Japan), as shown in Figure 21a, and was designed to move the cut material to the sewing position. Two templates were then produced, as shown in Figure 21b. Each was placed above and below the pattern that will be sewn to be moved using an automatic feeding system. The template was designed using two polycarbonate materials by drilling two shoulder lines and two
SewBot Is Revolutionizing the Clothing Manufacturing Industry
FEBRUARY 19, 2018
In Bangladesh the labor cost to produce a denim shirt is about $0.22. If made by U.S. workers, that labor cost jumps to $7.47, but with a robotic production line, it’s just $0.33 per t-shirt.
Work aids are Additional devices that can be added to basic sewing machines such as folders, guides, and pressure feet. If work aids are used effectively operation cycle time can be reduced many folds than existing cycle time.
The Evolution of Productivity Management - Important Contributors and Their Contributions and Systems
Importance of productivity improvement was highlighted by the first President of ASME in 1880. Henry Towne in 1886, presented a paper in ASME Conference strongly highlighting the need for engineering efforts to reduce cost of production on a continuous basis. He also presented a paper in 1889 explaining the method followed in his company to involve all production/shop employees in cost reduction effort.
F.W. Taylor responded to these cost reduction calls by explaining the initiatives he had taken. in 1893, he presented his paper on the improvements done in the area of belt design to reduce overall cost belt systems that included installation cost, maintenance cost and operation time lost due to maintenance time. In 1895, he presented a full explanation of the productivity improvement system utilizing study and reduction of time taken by machines and men to do elementary activities that are present in multiple different engineering jobs. Then he advocated fixing of piece rates and daily rates that provided additional income or higher wages to operator to learn and use new methods and produce higher output. In this paper, he suggested organizing a rate fixing department, that later on became industrial engineering department that takes the responsibility of improving productivity in engineering organizations. This paper became popular as piece rate system. F.W Taylor is regarded as the father of industrial engineering for this engineering innovation in the area of organizing engineering knowledge or practice.
Ian Rolland
Chairman and Chief Executive Officer of Lincoln National Life Insurance Company
and President and chief executive officer of Lincoln National Corporation Company in Fort
Wayne, Indiana.
Robert Janson
Executive vice-president of Roy W. Walters & Associates, Inc., consultants to management, in Mahwah, New Jersey.
California Management Review, WINTER / 1981 / VOL. XXIV / NO. 2, pp. 40-48
• Productivity is a long-term survival issue. Unless a company focuses on productivity as a key
ingredient of their corporate philosophy, it won't survive.
• Companies must plan for productivity. Productivity does not just happen. It requires a strategy that is comprehensive, long-range, and monitored. It requires rational, purposeful behavior on the part of everyone.
• Employee security must be assured. Productivity should not be looked at as cost cutting or it
will make people insecure. This does not mean that they won't be doing different things, however.
• Employee involvement is the key ingredient to productivity. Management must create a
structure that focuses people's energy inward to their own jobs and organization rather than
how unhappy they are or how bad the organization is.
• Ownership and commitment are essential. Unless everyone feels part of the effort and looks on it as something that will help them, it won't work.
• Productivity and individual responsibility work together. An organization should be designed
for accountability to the lowest possible level. This requires in many cases a broad redesign
of tasks and jobs.
• Productivity is a very complex issue. The important thing is to have a strategy that is long term,
with measurable goals. Individual units will have different applications.
• A good strategy will have multiple phases. The effort should not be looked at as a "quick
fix." It takes time to move the organization in a new direction.
• Productivity strategies must support and strengthen the business mission. The mission
of the company, with its goals and objectives, comes before individual productivity efforts.
David J. Sumanth (1984)
Productivity management is a formal process involving all levels of management and employees with the ultimate objective of reducing the cost of the manufacturing, distributing, and selling of a product or service through an integration of the four phases of the productivity cycle, namely, productivity measurement, evaluation, planning, and improvement.
D. Scott Sink (1985)
Basic Productivity Management Process includes the following: (1) measuring and evaluating productivity; (2) Planning for control and improvement of productivity based on information provided by measurement and evaluation process; (3) making control and improvement interventions; and (4) measuring and evaluating the impact of these interventions.
The essence of productivity management process is to direct and motivate productivity planning and action through the productivity measurement system.
A Synopsis of Productivity Management
Productivity management involves planning, organizing, leading, controlling, and adapting processes, technologies, output and inputs based on the relationship between quantities of outputs (including in revenue/price terms) from a system and quantities of input (including in cost/price terms) to the system. Productivity management is an important planning and control function like other management functions. But, there is a growing concern that it has been overlooked and that it needs to be better developed.
In the 1985 book, Scott Sink expressed the opinion that there are no significant breakthroughs. Much of the success in Japan and elsewhere appears to result from more effective implementation.
Productivity managers have to understand the various functions that contribute to the creation of goods and/or services. They have to take a large strategic view of the system and examine the individual machines and operators to make productivity improvements that are alignment with the productivity strategy and show measurable results.
All activities of overall management which determine productivity policy, productivity planning, productivity audit, productivity monitoring and control, productivity measurement, productivity evaluation, organisational structure, procedures, processes and resources to implement productivity improvement programmes and policy.
Narayana Rao Kambhampati (2017)
Productivity management is included as a principle in principles of industrial engineering.
(Kambhampati, Venkata Satya Surya Narayana Rao, "Principles of Industrial Engineering", IIE Annual Conference. Proceedings; Norcross (2017): 890-895). https://nraoiekc.blogspot.com/2017/06/productivity-management-principle-of.html
Productivity management
Productivity management is the responsibility of industrial engineers. Productivity management practice has two areas of focus in industrial engineering. One is an evaluation of management processes and plans for their impact on the productivity of engineering activities and processes. If the evaluation shows that productivity can change due to change in management process or plan, industrial engineers have to come up with redesigns and recommend them to management at various levels. Due to this component, industrial engineers have to learn management principles and
methods in various industrial and business functions.
The second component is the application of management theory and practice to the task of productivity improvement. Every industrial engineer is a productivity manager. He has to learn complete management theory and its application in IE practice.
Developing the organization's productivity strategy in various sectors of industry
Peter Oeij
2012, International Journal of Productivity and Performance Management
Your productivity is a work done in certain period.
More work done in the same period with the same resources increase productivity.
You need to get organized to be more productive.
You need to be more focused on your work if you want to be more productive.
Good execution plans can increase your productivity.
You need improve your process and systems if you want to accelerate performing the same job.
Your personal life have influence on your business life and productivity.
Everything varies wildly from day-to-day, from month to month, from year to year…
Working with passion can bring more work done.
Enjoying what you work will help you to do more work.
Inspiration is the productivity creator.
Negative individual emotions have a negative effect on your work done.
Preparation will increase possibilities of quality of the work you done.
Focus on the desired results will increase a possibility of quality accomplishment.
There will be always the possibility of improvement.
Tracking the progress will improve your work done over the time.
Lists are a very useful stuff.
Finding constraints and cut them permanently will increase personal and business efficiency.
Outsourcing of unimportant stuff will help you.
First do the most important things.
Help from other people is welcomed and accepted.
If you finish easier tasks as first, you will increase your overall productivity.
What you can to do today, do it today, not tomorrow.
Your productivity in many cases will depend on the productivity of your environment.
Physical environment can influence your productivity.
Taking a short break will improve your personal productivity.
Refreshing the mind give us additional energy.
Accepted criticism make better work done in the shorter period.
Distraction has a negative effect on you.
Learning from other people and businesses will give you possibilities to escape their mistakes.
Stress has a negative effect on work you done.
Celebrating success with your team will give you and your team additional potential energy.
Self-confidence is important.
Proactive, not reactive is the basis for success.
Notebooks are useful when something important comes to our mind.
It is normally that nothing goes right all the time. Technology is here to help you. Don’t escape from the new technology. Do not be afraid if you don’t know how to use something new.
Everything can be learned.
Everything can be systematized. Everything can be improved and simplified.
Posted by Dragan Sutevski
Dragan Sutevski is a founder and CEO of Sutevski Consulting, creating business excellence through innovative thinking.
