Learn Industrial Engineering the practical way
Free articles, Excel templates and calculators on IE, Excel and the garments industry - written from real factory experience.
Store & InventoryMaterial issue, leftover return and order reconciliation
Issuing fabric and trims against requisitions, controlling extra issues, returning leftovers, and closing each order with a fabric and trims reconciliation.
Store & InventoryInventory control: ABC analysis, reorder level and cycle counting
Sort items by value with ABC analysis, set reorder and maximum levels for running items, and keep stock accurate with cycle counts instead of one big yearly count.
Thread size systems explained: Tex, denier, cotton count, metric count and ticket number
Why thread is sized by weight, not thickness; direct vs indirect systems; how Tex, denier, cotton count (Ne), metric count (Nm), ticket number and embroidery "weight" convert - plus which thread and needle suit which fabric.
Store layout, bin locations and FIFO
How to lay out racks and aisles, give every location an address, keep bin cards, store fabric rolls safely and make FIFO work in practice.
Store & InventoryReceiving and inspecting fabric and trims: 4-point system and trim checks
How to receive and inspect fabric rolls with the 4-point system, calculate points per 100 square yards, check trims against the trim card, and handle rejects.
Store & InventoryStore and warehouse in a garment factory: what it does and why it matters
Fabric store, trims (accessories) store, finished goods warehouse and machine-parts store - the material flow, the documents at each step, and the store KPIs.
Excel logic and summaries: IF, SUMIF, COUNTIF, FREQUENCY and Pivot tables
Decide with IF, add and count with conditions using SUMIF and COUNTIF, group values with FREQUENCY, summarise thousands of rows with a Pivot table - and combine IF, CONCATENATE and SUMIF for a running balance.
Excel lookup formulas: VLOOKUP, HLOOKUP, INDEX, MATCH and CHOOSE
Find any value in a table: when to use VLOOKUP or HLOOKUP, why INDEX + MATCH is more flexible, and how CHOOSE switches between ranges - with simple examples you can copy.
Built-in quality, TQM and the cost of quality
Why quality must be built at every step instead of inspected at the end, the 7 principles of Total Quality Management, and the four costs of quality every factory pays.
Calculators for everyday IE work
Target, efficiency, line balancing, man machine ratio, machine requirement and time study.
Templates & guides
Excel, PDF and Word files, ready to use. Files marked 🔒 are for members.
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