Industrial Engineering Calculations in garment production factory

Industrial engineering calculations in a garment factory


Industrial engineering calculations in garment production factory is the most powerful waste quantifying and reduction tool.

These calculations are important because without setting up a target it is highly unlikely that you will be able to achieve what is expected. Once the target is set and we know what is expected we can take steps to achieve the target production. It gives industrial engineers clear picture about the performance of sewing operators, supervisors and the sewing line. The things that an industrial engineer needs to calculate are: capacity, efficiency, performance and utilization.

Knowing I.E terms:

  1. On standard  time – The time spent in doing measured work  is called On Standard time example – stitching, bundle handling etc.Any work for which S.A.M has been applied will be On standard.
  2. Off standard – The time spent in doing unmeasured or non-value adding work is called Off standard time. Example – Machine breakdown, waiting time etc.
  3. SMV – The time taken by a 100 % rating operator to complete an operation.
  4. SAM = SMV+ allowances

Capacity

The number of garments a factory is capable to produce is called capacity of factory. Capacity calculation helps in planning of resources. Example:
If the SAM of a shirt is 25 mins, how many of these shirts can a factory, having 200 workers who are working 48 hours a week, produce in a week?
Ans :

Capacity calculation formula for a sewing line
Capacity calculation formula for a sewing line

Therefore,Capacity = (200*48*60)/25

= 23040 garments in a week 

Note : We multiplied by 60 to convert hours into minutes.

Performance, Utilization and Efficiency 

  1. Performance :

    Performance is primarily the Measure of effectiveness of individual operator. It tells how well an individual operator is performing.

    Sewing operator performance formula
    Sewing operator performance formula

    Where ,

    Minutes earned on Std. = No. of pieces produced * S.A.M 

    Time spent on Std = Total available time – total off standard time

    Note : We are subtracting total off standard time from total available time because here we are calculating operators performance. Machine breakdown, waiting and other off standard time is not under the control of the operator. Supervisor/manager is responsible for keeping off standard under check. 

2. Utilization

Utilization is  the measure of how well a supervisor is able to use the operators by keeping the off standard to minimum.

Sewing operator utilization formula
Sewing operator utilization formula

Where,

Time spent on Std. = Total available time – Off Std. time

Total available time = total worked minutes. 

Note : Here we are checking the performance of supervisor therefore we will use total available time and divide On standard time by total available time. Main goal here is to find the amount of off standard.

3. Efficiency

Measure of how well the sewing line is run. It is the combined measure of both the performance and Utilization.

Sewing efficiency formula
Sewing efficiency formula

Note : In efficiency calculation we use both the available minutes and Minutes earned by actual production because we want to measure the performance of the complete sewing line. This formula undertakes both the operator and supervisors performance, that is Performance and Utilization in calculation.

Let’s Calculate performance, utilization and efficiency now:

Operator Jay attends, full day/480 minutes, and produces 1000 pieces at SAM of 0.40. He had to wait 50 minutes for work and 10 minutes for machine breakdown. Calculate the operators performance, Utilization and efficiency.

Ans: Standard minutes produced = 1000*0.40 = 400 minutes

Time on standard = 480-(50+10) = 420 minutes

Performance = 400/420 = 95.2%

Operator Utilization = 420/480 = 87.5%

Operator Efficiency = 400/480 = 83.3 %

Here is the excel file template with formula. Download it for recalling the formula quickly and for easy industrial engineering calculations in garment production factory.

Industrial engineering calculations template

 

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