Skip to main content

How to calculate different efficiency in garment industries

I

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.   

Labels:

Comments

Post a Comment

I hope the above details useful for you.
Share your topic to get articles.
Share it if useful to someone.

Popular posts from this blog

12 FACTORS TO CALCULATE ACCURATE THREAD CONSUMPTION

  12 FACTORS TO CALCULATE ACCURATE THREAD CONSUMPTION  What is thread consumption per garment? How many threads required to sew a garment is called thread consumption. Sample selection for thread consumption calculation is very important, we have to select the right sample and size. Thread consumption calculation should consider proper allowance to avoid thread shortage or exceeding. Even thread cost is low than other cost of garment materials, thread consumption calculation is a very sensitive process. Providing incorrect thread consumption may lead to issues in production and delivery. Thread consumption formula, Thread consumption = (Seam length x Frequency x Factor) / 100 + Allowances What are the facts that should be consider making an accurate thread consumption report. 1. Samples Type When we select the sample for thread consumption calculation, we must be checked the type of sample. As below mentioned there are many types of samples. In all of them, we ha...
6 comments
Read more

Dashboard report to monitor the factory performance

A. Introduction “Often, we hear that highly skilled leaders are struggling to succeed, So, what would be a reason for their struggle?”   In the garment manufacturing industries, solving the problem is not about skill what we have. It is about what kind of effective monitoring system we have. Unidentified issues are subsequently leading to the firefight at neck-movement. In this kind of circumstance, finding the remedial actions is a complex thing. Because. Our industry is depending on multiple man-oriented tasks and complex details. The successful leaders are developing the practice of key area monitoring. Monitoring the key function making us understand the organization's progress. B. What is the single window monitoring report? The good leaders in the organization are regularly monitoring the live details. In that most of them designed simplified “the single page monitoring dashboard- report” Here, the report is simple and covers a key part of the business process. Below...
4 comments
Read more

How to grade operators skill in the garment industries? For cutting, sewing and finishing section employees

A. Grading: Every employee is graded based on their actual skill known and actual performance. The grading process will be done by IE followed by the actual details of employees. Example: Process skill, Machine Skill, Actual performance, quality in their works, etc. the authenticated input is obtained from actual production report, skill matrix, and operators performance report. B. Type of grading: Grade A: Skilled operators Grade B: Semi-skilled operators Grade C: Basic Operators Grade D: beginner operators Grade E: None sewing process C. Grading wise process 1. SEWING SECTION: GRADE PROCESS MACHINES REMARKS A   1. Attach collar with band (Pick ready) 2. Attach Pocket (without mark) 3. Sleeve PLKT Diamond stitch 4. Sleeve Attached 5. Side seam Feed of Arm 6. Attach Cuff with pleat 7. Finish Round patch bottom (cut/sew) 8. Waist band close SNLS E/C SNLS / DNLS SNLS SNLC ...
3 comments
Read more