Interview questions for Industrial Engineering Job in Apparel industry
6. What is CPM & CM?
Answer: CPM is cost per minute. It may be for a production line or a factory or an organization.
CPM (Cost per Minutes) = (Direct Labor Cost + Operational Cost) of the month/ Usage Minutes (Available Minutes) of the month
CM or COM is cost of making or making cost. In broad sense it is CMT (Cut, Make & Trim) cost for garments industry. Before finding CM, CPM must be calculated.
CM= (SMV × CPM)/ Expected Efficiency%
Suppose, any item SMV is 5.5, Expected efficiency = 62.5 %, CPM= $0.03
CM = (5.5 × .0264)/ .625
= ($0.264 ×12)/ Dzn
=$3.168 / Dzn
7. What is rating? What are the factors affecting rating?
Answer: Rating is the effective measure of an operator to show his/her skill based on benchmark & pre-defined condition. There is commonly used standard rating scale. They are 0, 1-50, 51-75 & 76-100, but this though changing gradually. In recent, most companies have their own range based on their standard operator, their performance, basic time & work quality. 1 to 100 may be segregated in several ranges as per work standard.
RATING= (OBSERVED RATING × STANDARD RATING)/ STANDARD RATING
The common factors affecting rating are:
1. Work measurement technique & accuracy
2. Time duration to fix the rating
3. Work quantity
4. Work quality
8. What are the objectives of work study & method study?
Answer: Objectives of work study are:
1. Cost optimization
2. Increase productivity
3. Increase profitability
4. Increase jobs security
5. Standard work procedure
6. Establish fair task for every one
Objectives of method study are:
1. Improve layout of factory and office
2. Better design of plant equipment and buildings
3. Higher standard of safety and health
4. To improve the flow of work
5. To get the better quality
6. Effective materials handling
7. Proper utilization of resources
8. To get maximum output
9. To improve administration
10. Waste reduction
9. Describe the principles of motion economy.
Answer: There are three principles of motion economy. They are:
1. Use of human body
2. Arrangement of the work place
3. Design of tools and equipment
Use of human body:
1. The two hands should begin and complete their movement at the same time.
2. The two hand should not be idle at the same time accept during the period of rest.
3. Motion of the arm should be symmetrical and in opposite directions should be simultaneously.
4. Ballistic (free swinging) movement is faster, easier and more accurate than restricted movement.
a) “Rhythm” is essential for a sewing operator to the smooth and automatic performance of a repetitive operation. The work should be arranged to permit easy and natural rhythm whenever possible.
b) Work should be arranged so that eye movements are confined to a comfortable area without the need for frequent changes of focus.
Arrangement of the work place:
1. Definite and fixed stations/place or location should be provided for all tools and materials to permit habit formation.
2. Tools and materials should be re positioned to reduce searching.
3. Tools, material control should be located within the maximum working area and as near to the worker as possible.
4. Tools, material control should be located within the maximum working area and as near to the worker as possible.
5. A comfortable chair should be provided. It should be possible for the worker to put both knees under the bench.
6. Adequate natural or artificial lighting should be provided.
Design of tools and equipment:
1. The hand should be relieved of all work of holding the work place where this can be done by jig, fixture or foot operated device.
2. Two or more tools should be combined wherever possible.
10. Write is bottleneck & line balancing?
Answer: Bottleneck is a phenomenon by which the performance or capacity of an entire system is severely limited by a single component. In production and project management, a bottleneck is one process in a chain of processes, such that its limited capacity reduces the capacity of the whole chain. Bottleneck, which are holding up production operations, or lengthy operations, that consumes a great deal of time. Bottleneck may be any process, any machine or any operator.
Line balancing is a manufacturing engineering function in which whole collection of production line tasks are divided into equal portions. Well balanced lines avoid labor idleness and improve productivity. Sometimes imbalanced line causes bottleneck.
Line layout→Capacity study→Capacity graph→Find bottleneck→Method engineering→Line balancing
11. What are 8W of garment manufacturing? Write down name & describe shortly.
Answer: Waste is any step or action in a process that is not required to complete a process or that is non-value added activity. 8W means eight wastage. They are:
1. Motion: Excess motion increase garment manufacturing time. Like turning, bending, lifting, moving etc.
2. Inventory: Inventory is a loss that reduces profit. Like stored parts, equipment, materials, documents etc.
3. Transportation: Excess transportation increases garment manufacturing time. Like movement of people, materials, information etc.
4. Waste: Waste is a loss which reduces profit. Like waste material, parts, equipment etc.
5. Overproduction: It is one kind of inventory. Like producing or making more than requirement.
6. Over processing: It increases garment manufacturing time & cost. Like beyond tolerance or grade or number etc. than required.
7. Defect: It decrease garment quality as well as increase nonproductive time. Like rework, correction, scrap, incorrect data fixing etc.
8. Skill: It is the root of loss, less efficiency or non-productive time. Like underutilized capacity, less or no trained worker etc.
12. What is 6S? Shortly describe.
Answer: 6S is a systematic approach to workplace organization. It is an explanation of the lean manufacturing 5S method and how to use it to create a safer workplace (sometimes known as 6S or 5S + Safety).
1. Sort (Seiri): Find out necessary & non-necessary stuff
2. Set in order (Seiton): Set stuffs in top necessity to less necessity
- Shine (Seiso): Eliminate non-necessary stuffs
- Standardize (Seiketsu): Making a standard way or strategy
- Sustain (Shitsuke): Making previous steps sustainable
- Safety: Safe work environment & personal safety