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How to calculate different efficiency in garment industries

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1. Introduction

Producing ability is measured as efficiency in the garment industry. This is a measure used to understand the degree of producing capacity within the given time. It is a ratio of time and production.

2. How to calculate efficiency?

A simple formula to calculate efficiency,  

Efficiency = (SAM x Production) / Available time x 100

Example1: SAM = 0.5, Production = 500, Available time = 480min

Efficiency = (SAM x Production) / Available time x 100

            = (0.5 x 500) / 480 x 100

            = 250 /480 x 100

Efficiency = 52.08% ----------------------------------------------------------------(a)          

3.       Different kind of efficiency and how to calculate?

a)      How to calculate operator efficiency

To measure the operator producing ability, we calculate the operator’s efficiency.

Formula

Operator efficiency for a day = (SAM x Production) / Available time x 100

Example2: Operator efficiency calculation for a day.

If SAM = 0.6, Production = 600, Working minute = 480, then calculate efficiency.

 

Eff  = (SAM x Prod) / Avl Time x 100

       = (0.6 x 600) / 480 x 100

Eff  = 75 %

Efficiency achieved = 75% -------------- (b)

Pie Chart for Efficiency achieved of 75%  

 Formula

Operator efficiency for a month = (SAM x Production) / (Work days x Available time) x 100

Example3: Operator efficiency calculation for a month.

If SAM = 0.6, Production = 12,500 pcs, Working minute = 480, working day = 25 days, then calculate efficiency.

 

Eff=(SAM x Prod) / (Working day x Avl Time)x100

      = (0.6 x 12,500) / (25x 480) x 100

      = 7500 / 12000 x 100

Eff = 60 %

Efficiency achieved = 60% --------------- (c)

Pie Chart for Efficiency achieved of 60%  

 b)      How to calculate line efficiency

Line efficiency is calculated based on the line produced, manpower utilized, and working minutes. Line efficacy is denoting the group efficacy of the particular line.

Formula

Line efficiency for a day = (SAM x Production) / (Manpower used x Available time) x 100

Example4: Line efficiency calculation for a day.

If SAM = 20, Production = 550 pcs, working minute = 480, manpower = 40 days, then calculate efficiency.

 

Eff=(SAM x Prod) / (manpower x Avl Time)x100

      = (20 x 550) / (40x 480) x 100

      = 11000 / 19200 x 100

Eff = 57.29 %

Line Efficiency = 57.29% --------------- (d)

Pie Chart for Efficiency for 57.29%  


Formula

Line efficiency for a month = (Avg.SAM x Production) / (Manpower used for month x Available time) x 100

Example5: Line efficiency calculation for a month.

If Avg. SAM = 20, Production = 14000 pcs, working minute = 480, total manpower = 950 days, then calculate efficiency.

 

Eff=(Avg.SAM x Prod) / (manpower x Avl Time)x100

      = (20 x 14000) / (950x 480) x 100

      = 280000 / 456000 x 100

Eff = 61.4 %

Line Efficiency = 61.4% --------------- (d)

Pie Chart for Efficiency for 61.4%  


4.       What is the meaning of performance?

Performance is similar to efficiency the calculation, only loss time is reduced from available time

Formula

Performance = (SAM x Production) / (Available time-Loss time)  x 100

a)       What is the meaning of downtime or loss time?

Loss time is also called downtime due to electricity down, No feeding, Machine breakdown, Rework time, etc.

b)      How to calculate performance

Performance  = (SAM x Production) / Available time-loss time x 100

Example:4:

SAM = 0.6, Production = 600, Loss time = 60 min, Working minutes = 480 minute then

 Performance     = (0.6 x 600) / (480 – 60) x 100

                           = 360 / 420 x 100

Performance      = 85.71 % ---------------------------------------- (e)   

Efficiency  = (0.6 x 600) / 480 x 100

                   = 360 / 480 x 100

Efficiency =  75.0% --------------------------------------------- (e’)

Here (e) and (e’) are calculated the performance and efficiency for the same values.  

Correlation for same vales

Efficiency = < Performance ---------------------------------- (f)

5.       What is the difference between efficiency and performance?

Efficiency is calculated based on available time, Performance is calculated after reduced loss time in the available time. For example, available time is 480 minutes and Loss time is 80, in this case, 480-80 = 400 minutes considered for calculating performance.   

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