Program Overview
This industry-focused program, led by a seasoned expert with 25+ years of experience, equips participants with hands-on skills in work study, SAM, and line balancing to transform shopfloor efficiency. Participants will explore IE concepts tailored to garment production, calculate SAMs using real data, balance line layouts for optimal flow, and reduce productivity losses using tried-and-tested techniques. With interactive simulations, tools, and real-life examples, attendees will return to the shopfloor equipped to deliver measurable productivity improvements and on-time delivery—without additional resources or headcount.
Features
- Apply SMV/SAM concepts accurately using time study and synthetic data
- Design balanced line layouts to eliminate bottlenecks and reduce WIP
- Identify and analyze real-time production losses and workflow inefficiencies
- Implement targeted IE interventions to improve line efficiency and output consistency
Target audiences
- Lean / TPM / Continuous Improvement Teams
- Quality & Ops Teams
Curriculum
- 3 Sections
- 14 Lessons
- 1 Day
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- Industrial Engineering — The Engine of Apparel Factory Productivity4
- 1.1What IE delivers beyond data: Cost control, efficiency, on-time delivery
- 1.2Key terms: SAM (Standard Allowed Minute), SMV (Standard Minute Value), Takt Time, Efficiency %, Line Balance %, OEE
- 1.3IE’s role in pre-costing, production planning, process design
- 1.4Example: How accurate SMV helped an exporter avoid margin loss
- Work Study & SAM — The Heart of Factory Costing5
- 2.1Work Study process: Method study + Time study
- 2.2Steps to develop accurate SAM
- 2.3Factors: Machine time, allowances, motion economy, rating
- 2.4Basic time, standard time, synthetic data, PMTS (Pre-determined Motion Time Systems)
- 2.5Activity: Develop a SAM for a simple operation (e.g., pocket attachment) using given data
- Line Balancing — Theory to Factory Floor5
- 3.1The impact of imbalance: bottlenecks, WIP pileup, low utilization
- 3.2Line balancing method: balance chart, balancing loss %, cycle time alignment
- 3.3Lean + IE integration: Pull systems, modular lines
- 3.4Case Study: Line balancing reduced bottleneck delays in a knitwear line by 20%
- 3.5Case: Line balancing reduced bottleneck delays in a knitwear line by 20%
Instructor
