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Industrial Engineer-IE
Job Interview Questions & Answer
Engr. Md. Shahriar Hossain
DG (Textile), BSc (Apparel)
MBA- Rajshahi University

1. What is Efficiency?
The comparison of what is produced or performed with what can be achieved with the same
consumption of resources (money, time, labor, etc.)
So, Efficiency=SMV*Production/M/P*W.H(min)*100%

2. Write down The name of Efficiency drivers.

a. SMV
b. Production
c. Manpower &
d. Working Time.

3. What is SMV?
(Standard minute value) The Standard time required to manufacture a complete product is
called SMV.
Write down The name of Efficiency drivers.
1. Standard Manpower,
2. Standard Environment,
3. Standard Machine &
4. Standard Method.

4. What are the factors of SMV in the Apparel Industry?

a. Types of Apparel
b. Types of fabric
c. Size of Apparel
d. Design of Apparel
e. Difficulty of the processes
f. Types of M/C and technology used
g. Use of work aid, folder, attachment, etc.

5. What is Basic Time?

The primary time for the operation is found by applying the concept of rating to relate the
observed to that of a standard place of work.

6. What is Standard time?

The standard time is the total time the job should be completed at the standard level.
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7. What is Target?
Target is the amount of production that an Operator should produce.

8. What is Observed Time?

The time was measured to complete a task.

9. What is Cycle time?

Cycle time is the time it takes to complete the production of one unit from start to finish.

10. What is WIP?

The same finished/finished goods transported from one workstation to the next are called
WIP.

11. What is Pitch Time?

Total SMV divided by the number of Workers.

12. What is a Learning Curve?

The time taken to achieve the plan target is called the learning curve.

13. What is the rating?

Rating is the technique used to assess an Operator’s or worker’s speed and effectiveness.

14. What is Style feeding time?

Time is taken to output the first piece of a new style from the first machine of input to output.

15. What is production?

Production generally refers to activities that convert resources into products.

16. What is productivity?

Productivity is the ratio between output & input.

17. What is method study?

Method study is the study of work method for a job to achieve process improvement, improve
the layout, improve design & reduce fatigue & cost for developing a more accessible and
effective way.

18. Write down the steps of the Method Study.

1. Select
2. Record
3. Examine
4. Develop
5. Define
6. Install &
7. Maintain
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19. Objectives of Method Study?

1. Lower The cost.
2. Increase the productivity
3. Increase the profitability.
4. Increase the job security.
5. Fair task for everyone, etc.

20. What is Motion Study?

Motion study is the systematic examination of carrying activities to input the effective use of
resources & to set up standards & performance for the activities being carried out.

21. What are the main activities of IE?

1. System development
2. Process analysis& implementation
3. Reduced cost
4. Increase production & productivity

22. What is line balancing?

To put the correct operator to the proper process called line balancing.

23. What is the bottleneck?

High cycle time of an individual process or dumping any operation where production&
productivity do not come.

24. What is Balancing loss?

1-lowest target/Hight target*100%

25. How to increase Efficiency?

1. Increase production& productivity
2. Reduced Extra overtime
3. Reduced NPT
4. Reduced QCO time
5. Multiskilled operator creating
6. Proper utilization of machine

26. What is MMR?

Man 2. Machine 3. Ratio

27. How to calculate MMR?

Total manpower\total run machine.

28. What is Load?

How much work are we putting into a section?
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29. What is Capacity?

How much work a section is capable of working?
30. What is Lean?
Lean manufacturing refers to manufacturing methodologies based on maximizing value &
identifying & eliminating waste in the manufacturing process.

31. Types of Lean?

1. Value added
2. Non-Value added
3. Wastage

32. What is Lean Manufacturing?

Lean Manufacturing is a production methodology that focuses on minimizing waste within
manufacturing systems while simultaneously maximizing productivity. It aims to create more
value for customers using fewer resources by improving efficiency, reducing costs, and
eliminating activities that do not add value to the final product. (Supplier -delivery ( Shorter
lead time).

33. What is Kaizen?

Kaizen is a Japanese term that means "change for the better" or "continuous improvement." It
refers to a philosophy or approach that focuses on the continuous improvement of processes,
products, or services through small, incremental changes. (Continuous Improvement).

34. What is Kanban?

Signal a visual card.

35. What are 5s?

1. Sorting
2. Set in order
3. Shine
4. Standardize
5. Sustain

36. How do we reduce the QCO?

1. Maintain pre-production activities
2. Proper line balancing
3. Smooth supply chain management

37. What is standard efficiency?

Produced min\available min-NPT*100%

38. What are PMTS?

Predetermined motion time system.
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39. What is LCL?

Lower control limit.
40. What UCL?
Upper control limit.

41. What is work measurement?

Work measurement is the application of an individual worker performance growth where
selecting an op to do any operation how effectively done.

42. Write down the wastage of lean.

1. Transportation
2. Inventory
3. Motion
4. Waiting
5. Overproduction
6. Over-processing
7. Defects

43. Does the rating depend on the?

1. Skill
2. Effort
3. Condition
4. Consistency

44. Types of allowance?

1. Relaxation Allowance
2. Fatigue allowance
3. Machine Allowance

45. What Is the Role Of IE?

Industrial Engineers Find ways to eliminate waste in the production process.

46. What Skill does an IE need?

a) Creativity
b) Critical Thinking Skills
c) Listening Skills
d) Problem-Solving Skills
e) Math Skills.

47. What are the IE Tools On the Quality base system?

a) Causes & Effect Diagram
b) Sheet
c) Control Chart
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d) Histogram
e) Pareto chart
d) Scatter Diagram
e) Stratification

48. What is Fish Bone Diagram?

Problem Solving Method Based on Man, Machine, Method, Material etc.

49. What is VSM?

Value stream Mapping is a potent tool used to identify waste in the entire value stream,
defined as activities required to control raw material into finished goods.

50. What does VE mean?

Value Engineering

51. How is VE Applied?

Formal Job Plan b) Trained Facilitator c) Function Analysis

52. When VE Applied?

a) Problem Solving,
b) Strategic Planning
c) New Product development.

53. What is the TPT Tracker?

Through Put Time. It calculates the time from start (layout) to finish time.

54. GSD Means?

General Sewing Data.

55. How many GSD Tasks are used in the garments industry?
Two GSD Tasks are used in the garments industry.

56. What are the tasks of GSD?

a) Low tasks,
b) High Tasks.

57. What do G and P mean in GSD?

G=Get data P= Put data

58. Write down Get Data in GSD.

To touch something is to Get data.

59. Write down Put Data in GSD.

To carry from one place to another.
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60. T.M.U=?
Time Measuring Unit
61. MTM =?
Methods Time Measurement.

62. 1 Sec=?
T.M.U( High Tasks) 33.3 TMU

63. 1 Sec=?
T.M.U( Low Tasks) 27.8 TMU

64. How many GSD codes are used in the Garment industry?
37 Codes GSD codes are used in the Garment industry.

65. What type of Line layout is in the Garment Industry?

a) Line with center table and operator faces the same direction
b) Line with center table and operator face opposite direction
c) Straight layout
d) Side by Side
e) U-shaped layout
F) Modular line layout

66. What is TML?

Theoretical Mining Label

67. What is AML?

Actual Mining label

68. Write down work measurement techniques.

1. Time study
2. Method Study
3. Production Study
4. Activity sampling
5. PMTS
6. Analytical estimation

69. Write down five uses of SMV:

1. Pre costing calculation
2. Planning
3. Line Balancing
4. Efficiency Calculation
5. Issue targets
6. Calculate cost per minute.
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70. Write down Six significant losses.

1. Breakdowns
2. Setup
3. Small Stops
4. Reduced Speed
5. Startup Rejects
6. Production Rejects

71. What is CPM & CM ?

CPM cost per minute. It may be for a production line, 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 the cost of making or making cost. In a broad sense, it is CMT (Cut, Make &
Trim) cost for the 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/PCs
= ($0.264 ×12)/ Dzn
=$3.168 / Dzn “

72. What do you know about tact time?

The average time between the start of production of one unit & the start of production of the
next unit, when these must be set to match the rate of customer demand, is called takt time. In
short, it reflects the production rate needed to match the demand.
T=Ta /D
Where T=Tact time
Ta=Net available time
D=Demand
Net available time is the time for work completion, including break time, maintenance, loss
time, brainstorming, etc.”

73. What do you understand by 5D?

Absence of 5S on the production floor results in five devils or 5D. They are:
1. 1D-Delays
2. 2D-Downtime
3. 3D-Defects
4. 4D-Dangerous (Unsafe) workplace
5. 5D-Demoralized employees
All 5D results in dissatisfied customers & decreased profit.”

74. What are the objectives of the work-study?

Objectives of work study are:
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1. Cost optimization
2. Increase productivity
3. Increase profitability
4. Increase job security
5. Standard work procedure
6. Establish fair tasks for everyone

75. What are the Objectives of the method study?

1. Improve the layout of the 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

76. What is SMED?

SMED (Single-Minute Exchange of Dies) is a system for dramatically reducing the time
required to complete equipment changeovers. The essence of the SMED system is to convert
as many changeover steps as possible to “external” (performed while the equipment is
running) and to simplify and streamline the remaining steps. The name Single-Minute
Exchange of Dies comes from the goal of reducing changeover times to the “single” digits
(i.e., less than 10 minutes).

77. A successful SMED program will have the following benefits:

1. Lower manufacturing cost (faster changeovers mean less equipment downtime).
2. Smaller lot sizes (faster conversions enable more frequent product changes).
3. Improved responsiveness to customer demand (smaller lot sizes allow more flexible
scheduling).
4. Lower inventory levels (smaller lot sizes result in lower inventory levels).
5. Smoother startups (standardized changeover processes improve consistency and quality.

78. When to use the PDCA cycle?

Use the PDCA cycle when:
1. Starting a new improvement project
2. Developing a new or improved design of a process, product, or service
3. Defining a repetitive work process
4. Planning data collection and analysis to verify and prioritize problems or root causes
5. Implementing any change
6. Working toward continuous improvement.
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79. What is OEE & valuable?

OEE (Overall Equipment Effectiveness) is a “best practices” metric that identifies the
percentage of planned production time that is genuinely productive. An OEE score of 100%
represents perfect production: manufacturing only good parts as fast as possible, with no
downtime.
OEE is helpful as both a benchmark and a baseline:
As a benchmark, it can be used to compare the performance of a given production asset to
industry standards, to similar in-house assets, or to results for different shifts working on the
same purchase.
As a baseline, it can track progress in eliminating waste from a given production asset.”

80. What types of markers are used?

1. Mixed Marker
2. Open Marker
3. Closed Marker
4. Closed-On-Open
5. Blocking and re-laying
6. Single Section Marker
7. Section Marker

81. What is Industrial Engineering ?

Industrial engineering is a branch of engineering that focuses on optimizing complex
processes, systems, or organizations. It combines principles from various fields such as
engineering, management, and the social sciences to improve efficiency, productivity, and
quality in manufacturing and service industries.

82. What do you mean by Industrial Engineer?

Industrial engineers analyze and design workflows, production processes, supply chains, and
other systems to reduce waste, improve quality, and increase overall efficiency. They use
principles from mathematics, physics, social sciences, and engineering to solve problems
related to manufacturing, logistics, healthcare, service industries, and more.

83. Who is father of Industrial Engineering ?

The title "Father of Industrial Engineering" is often attributed to Frederick Winslow Taylor.
He was an American mechanical engineer who is best known for developing the principles of
scientific management, which laid the foundation for industrial engineering as a discipline.
Taylor's work focused on improving industrial efficiency and productivity, and his methods,
often referred to as "Taylorism," had a significant impact on manufacturing processes and
management practices in the early 20th century.

84. Job responsibility of IE Executive ?

The role of an Industrial Engineering (IE) Executive:
a) Process Improvement
b) Capacity Planning
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c) Workforce Management
d) Production Planning and Control
e) Quality Control
f) Cost Reduction
g) Data Analysis and Reporting
h) Technology Implementation
i) Health and Safety Compliance
j) Cross-functional Collaboration
k) Training and Development
l) Continuous Improvement

85. What is production target?

A production target is a specific goal set by a company or organization regarding the quantity
of products or goods that should be manufactured or produced within a particular timeframe.
This target helps in planning, resource allocation, and performance evaluation.

86. What is formula of Efficiency ?

Efficiency Formula:
Efficiency= (Actual Output / Expected Output)×100%

87. Full meaning of SMV ?

Standard Minute Value

88. What is 5M in Industry ?

a) Man
b) Machine
c) Material
d) Method
e) Measurement

89. What is 3M in Industry ?

a) Minnesota
b) Mining
c) Manufacturing

90. What is 5s ?
a) Seiri (Sort)
b) Seiton (Set in Order)
c) Seiso (Shine)
d) Seiketsu (Standardize)
e) Shitsuke (Sustain)

91. What is 7s in Industry ?

Strategy: The plan developed to achieve competitive advantage and organizational goals.
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Structure: The organization’s hierarchy and how tasks are divided and coordinated.

Systems: The processes and procedures that govern daily operations and activities within
the organization.

Shared Values: The core values and culture that guide the organization and its employees.

Skills: The capabilities and competencies of the organization’s workforce.

Style: The leadership approach and management style that influences the organization’s
culture and operations.

Staff: The organization’s human resources, including their roles, responsibilities, and
relationships.

92. What is 8 waste in garments industry ?

Overproduction: Producing more garments than necessary, leading to excess inventory

and increased storage costs.

Waiting: Time lost while waiting for materials, machines, or information. This can cause
delays in the production process.

Transport: Unnecessary movement of materials or garments, which can increase lead

times and costs.

Extra Processing: Performing more work or adding features that do not add value to the
customer. This can include unnecessary stitching or finishing processes.

Inventory: Excessive raw materials, work-in-progress, or finished goods that tie up capital
and increase storage costs.

Motion: Unnecessary movements by workers, such as reaching for tools or walking long
distances, which can lead to inefficiencies and fatigue.

Defects: Producing garments with defects that require rework or scrap, resulting in wasted
materials and labor.

Underutilization of Talent: Failing to utilize the skills and capabilities of workers, which
can lead to missed opportunities for improvement and innovation.

93. What is 5 waste ?

Overproduction: Producing more than what is needed or producing it too early, which
leads to excess inventory and waste.

Waiting: Time spent waiting for materials, information, or equipment. This can lead to
idle resources and lost productivity.

Transport: Unnecessary movement of materials or products between processes, which can

increase lead time and costs.
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Extra Processing: Performing more work or using more resources than necessary, such as
additional steps in a process that do not add value.

Defects: Producing defective products that require rework or scrapping, which leads to
wasted materials and labor.

94. Full meaning of ISO ?

International Organization for Standardization

95. Full meaning of BGMEA ?

Bangladesh Garment Manufacturers and Exporters Association

96. Full meaning of BKMEA ?

Bangladesh Knitwear Manufacturers and Exporters Association

97. Full meaning of TQM in Garments Industry ?

Total Quality Management

98. Full meaning of UCL ?

Upper Control Limit

99. Full meaning of LCL ?

Lower Control Limit

100. Full meaning of BOL in Garments Industry ?

Bill of Lading
In the context of garments, BOL typically stands for Bill of Lading. It is a legal document
between the shipper and carrier that details the type, quantity, and destination of the goods
being transported. In the garment industry, this document is crucial for logistics and
inventory management, as it helps track shipments and ensures that the right products are
delivered to the correct location.

101. Full meaning of SPI in Garments Industry ?

Stitches Per Inch

102. Full meaning of DHU in Garments Industry ?

In the garments industry, "DHU" stands for Defects per Hundred Units. It is a quality
control metric used to measure the number of defects found in a sample of garments, helping
manufacturers assess the quality of their production processes. This measurement allows for
identifying trends in quality issues and implementing corrective actions to improve overall
product standards.

103. Formula of CM in Apparel Industry ?

Cost of Manufacturing (CM)
Formula for Cost of Manufacturing (CM):
CM= Direct Materials + Direct Labor + Manufacturing Overhead
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Example Calculation

If a garment requires:

 Direct Materials: $5.00

 Direct Labor: $3.00
 Manufacturing Overhead: $2.00

Then, the Cost of Manufacturing (CM) would be calculated as follows:

CM=5.00+3.00+2.00=10.00\text{CM} = 5.00 + 3.00 + 2.00 = 10.00

CM=5.00+3.00+2.00=10.00

So, the CM for this garment would be $10.00.

104. What is CPM formula in Apparel Industry ?

In the apparel industry, the Cost Per Mille (CPM) formula is used to calculate the cost of
advertising per 1,000 impressions. It helps brands understand their advertising expenditures
in relation to their reach. The CPM formula is expressed as:

CPM= ( Total Cost of Advertising / Total Impressions ) × 1000

Example:
If a brand spends $500 on an advertising campaign that generates 100,000 impressions, the
CPM would be:

CPM=( 500 / 100,000 ) × 1000 = 5

105. What is basic time ?

In industrial engineering, basic time refers to the amount of time required to perform a
specific task or operation under ideal conditions, without any allowances for delays,
interruptions, or inefficiencies. It is an essential concept in time and motion studies, as it
helps establish a baseline for measuring the efficiency of work processes.

106. Rules of line balancing in Garments Industry ?

Line balancing in the garments industry is a crucial process that ensures the smooth and
efficient operation of production lines. It involves the allocation of tasks among workers or
workstations to minimize idle time, reduce bottlenecks, and ensure a continuous flow of
production. Here are some key rules and principles of line balancing in the garments industry:

1. Task Analysis:

 Break down the garment production process into smaller, manageable tasks.
 Analyze each task in terms of time required, complexity, and resources needed.

2. Workstation Design:
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 Design workstations to be ergonomic and efficient, minimizing unnecessary

movements.
 Ensure that each workstation is equipped with the necessary tools and materials to
perform its tasks efficiently.

3. Standard Time Calculation:

 Calculate the standard time for each task using time study methods such as the time-
motion study.
 Use these standard times to plan the workflow and balance the line.

4. Task Allocation:

 Distribute tasks among workers in a way that balances the workload across the
production line.
 Ensure that no single workstation becomes a bottleneck due to an excessive workload.

5. Skill Matching:

 Assign tasks to workers based on their skills and expertise to ensure quality and
efficiency.
 Train workers to be multi-skilled so they can handle multiple tasks as needed.

6. Workload Equalization:

 Aim to equalize the workload across all workstations to avoid idle time and maximize
productivity.
 Continuously monitor and adjust the line balance as necessary to maintain efficiency.

7. Bottleneck Identification and Elimination:

 Regularly monitor the production line to identify bottlenecks.

 Take corrective actions to eliminate bottlenecks, such as redistributing tasks or
adjusting the layout.

8. Use of Work Sharing:

 In cases where one task takes significantly longer than others, use work sharing to
split the task among multiple workers.
 Ensure that work sharing does not lead to confusion or errors in the production
process.

9. Continuous Improvement (Kaizen):

 Implement continuous improvement practices to regularly assess and improve line

balancing.
 Encourage worker feedback to identify areas for improvement in the production
process.

10. Flexibility and Adaptability:

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 Design the production line to be flexible, allowing for quick adjustments in response
to changes in demand or production schedules.
 Adapt the line balance as necessary to accommodate new styles or designs.

11. Effective Communication:

 Ensure clear communication among workers, supervisors, and management to quickly

address any issues that arise.
 Use visual management tools like production boards to track progress and identify
imbalances in real-time.

12. Technology Integration:

 Utilize technology such as automated sewing machines or computer-aided design

(CAD) systems to enhance line balancing.
 Implement software solutions for real-time monitoring and adjustment of line balance.

13. Waste Reduction:

 Focus on reducing waste in terms of time, materials, and effort by optimizing the
production line.
 Implement lean manufacturing principles to streamline processes and eliminate non-
value-added activities.

14. Quality Control Integration:

 Incorporate quality control checkpoints within the production line to catch and correct
defects early.
 Ensure that quality control does not interrupt the flow of production but is seamlessly
integrated into the line balance.

By following these rules, garment manufacturers can achieve a well-balanced production

line, leading to higher productivity, reduced costs, and improved product quality.

107. The step of method study for Industrial Engineering.

Method study is a fundamental aspect of industrial engineering, focusing on improving

processes and operations. It systematically analyzes work methods to enhance efficiency,
reduce costs, and increase productivity. The method study process typically involves the
following steps:
1. Select the Work to be Studied:

 Identify the process or operation that needs improvement. Selection is based on

factors such as high cost, frequent delays, or quality issues.

2. Record the Existing Method:

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 Gather detailed information about the current process. This can be done using various
recording techniques like flowcharts, process charts, or written descriptions. Accurate
data collection is crucial for understanding the current state.

3. Examine the Existing Method:

 Analyze the recorded information to identify inefficiencies or unnecessary steps.

Questions like "Why is this step necessary?" or "Can this be done differently?" help
uncover potential areas for improvement.

4. Develop the New Method:

 Based on the examination, propose a new method or process that eliminates

inefficiencies. The goal is to simplify, combine, or eliminate steps to achieve a more
efficient workflow.

5. Evaluate the New Method:

 Assess the proposed method in terms of feasibility, cost, and potential benefits. This
may involve testing the new method on a small scale before full implementation.

6. Define the New Method:

 Once the new method is proven effective, document it clearly. This includes detailed
instructions, new process charts, and any necessary training materials for workers.

7. Install the New Method:

 Implement the new method in the workplace. This step involves training employees,
adjusting equipment or layouts, and monitoring the transition to ensure it goes
smoothly.

8. Maintain the New Method:

 Regularly review the new method to ensure it continues to deliver the expected
benefits. Continuous monitoring and feedback from workers can help sustain
improvements and make further adjustments if needed.

These steps are iterative, meaning the process may need to be revisited as new issues arise or
as the operational environment changes. Method study is a continuous improvement tool that
helps industrial engineers optimize work processes, enhance productivity, and maintain high
standards of efficiency.

As an Industrial Engineer, you must be well-prepared to answer IE interview questions to

increase your chances of success in your dream job. You can improve your interview
performance and showcase your skills and knowledge in Industrial Engineering. With proper
preparation and the right mindset, you can confidently answer IE interview questions and
land your dream job in the Industrial Engineering field. So, remember to prepare for your IE
interview questions today to take your career to the next level.