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| IE Inerview Question and Solution |
v What
is SOP? Please Explain it.
v What
is cut to ship ratio?
v What
is SMED? What is BTB(Back to Back Feeding)?
v What
is SPI & TPI?
v What
is JIT(Just In Time)?
v What
is TMU?
v What
is MTM?
v
What is SOP? Please Explain it.
In garments & textile industry SOP is popular word &
new concept in this sector. In modern ages manufacturing company widely
maintain SOP for smoothly production process. SOP means “Standard Operating
Procedure”. It is the management tools of garments industry. It indicates the
every task how to operate smoothly. It is one kind of operating proceeding of
particular job.SOP is the checklist of particular task. Standard Operating
procedure is the success method of managing tools.
Basically, it is the written instructions of a particular
task. An operator can operate the particular task maintain SOP in his
department. Standard operating procedure is the complex task & need a
written draft before final implementation. Every department in garment &
textile sector has own SOP so they can operate smoothly every task for
successful operation.It is the effective
& efficiency way to successful operation of any organization.
v
What is cut to ship ratio?
‘Cut to Ship Ratio’ is one of the key
performance indicators of a garment manufacturing company. Here ‘cut’ means
total pieces cut by a factory for an order. And ‘ship’ means total pieces sold
to the customer (buyer) of an order.
For example, a factory gets an order of 1000
pieces, factory cuts fabric for 1020 garments (2% extra) and ship equal to 1000
pieces or less/higher than 1000 pieces
Calculation
method:
Cutting quantity = order quantity (1
+ extra cutting percentage)
Ship quantity = actual pieces shipped to buyer
Cut to ship ratio = (Cutting quantity / Shipped quantity)
Normally, factories those make export orders,
cut extra garments than the actual order quantity. In the garment making
process, there are possibilities of garment damage and rejection. So to ensure
that 100% order quantity is shipped to buyer after discarding damaged garment,
factories cut extra garments. Garment exporters generally cut 2-5% extra
garment than order quantity. Extra percentage of cut quantity is planned by
merchandiser or other authorised person.
Cutting of extra garments consumes extra fabric
and incurred excess cost of raw materials (fabric and trims) and increases
production cost to make those extra pieces.
There are few other reasons for cutting extra
garments than order quantity. Like, few buyers accept extra garments than order
quantity up to certain percentage with same FOB, in such cases factories try to
sell more garments to increase sales turnover. Secondly to utilize maximum
fabric that are sourced for a specific order. Percentage figure of extra
garment cutting varies depending on fabric types and number of processes
involved in conversion process from fabric to finished garment.
Reasons
for measuring cut to ship ratio of orders.
Some
of the reasons for measuring cut to ship ration are
·
To check how
efficiently a factory processes its orders
·
To Benchmark factory
performance in cut to ship ratio
·
How many pieces (in
percentage) are kept as surplus garments and analyse extra cost is incurred in
fabrics and labour cost
·
Performance of the
Factory Manager, General Manager is measured by cut to ship ratio figure.
How
to measure cut to ship ratio of an order?
To measure this ratio following information are
required
1.
Order quantity: This
information is available in the buyer's purchase order (PO)
2.
Total cut quantity:
This information will be available cutting department and production report
3.
Total shipped
quantity: This information is available with the shipping department and with
the merchandiser
Illustration: Suppose a factory received an export garment order of 10000 pieces
of shirts. Factory cuts 2% extra shirts as buffer and finally they have shipped
exactly 10,000 pieces to your buyer. Calculate cut to ship ratio for this
order?
Solution: 2% of 10,000 pieces is 200 pieces. That means factory cuts total
10200 pieces.
Therefore, Cut : Ship = 10200:10000 =1.02
v What is SMED? What is BTB(Back
to Back Feeding)?
v What is SPI & TPI?
SPI-Stich Per Inch
TPI-Twist Per Inch
v What is JIT(Just In Time)?
Just
in Time (JIT) means producing the right part in the right quantity, at the
right time, at the right place, thus reducing manufacturing waste. Just in time
is an inventory control system in which materials are purchased at the right
time and units are produced only as needed to meet actual customer demand
What
is TMU?
TMU
stands for Time Measuring Unit. In
Methods Time measurement (MTM) system, a predetermined time is given to each
motion. In motion study the time for each basic element is given in units of
TMU.
How many TMU is equal to one seconds
and one minute?
Conversion of TMU to hours, minute and second
1 TMU = 0.000010 hr = 0.00060 minute = 0.036 second
Or conversely
1 second = 27.78 TMU
1 minute = 1667 TMU
1 hour = 100,000 TMU
Application
of TMU in the apparel industry
For establishing the standard time (SAM) of
sewing operations by using the PMTS system, motion codes are applied for each
motion (movements) and each motion carries time in TMU. In Standard time
calculation, initially, standard time is measured and calculated in TMU. Later
the total TMU is converted into minutes.
v What is MTM?
MTM
is a procedure which analyzes any manual operation or method into the basic
motions required to perform it, and assigns to each motion a predetermined time
standard which is determined by the nature of the motion and the conditions
under which it is made.
MTM
gives values for the fundamental motions of: reach, move, turn, grasp,
position, disengage, and release.
