To set production target at daily production floor in garments industry, Standard Allowed Minutes (SAM) and Cycle Time both are necessarily used by production management team. Though it is depends on several factors but SAM or Cycle time are mainly used to calculate the Targets. Calculating and establishing correct production target is an important factor to drive productions because
if wrong calculated target are set then it will lose its achievable quantities within time because unrealistic target takes the worker in unrealistic situation which can be the reason of loss of product quality even. So therefore calculating correct Target is very vital as importance of catching correct SAM or cycle time is very important.Setting Targets Using SAM (Standard Allowed Minutes)
SAM represents the time allowed for a skilled worker to complete a specific task or a unit of work under normal working conditions. It accounts for the complexity of the garment and includes allowances for rest, fatigue, and other non-productive activities.
Steps to Set Daily Production Targets Using SAM:
1. Calculate the Daily Available
Minutes:
At first, calculate the total number of minutes available for production in a
day. This is typically based on the working hours of your factory and can be
calculated as:
Daily Available Minutes = (Worker × Working Hours per Shift × 60 minutes) ×
Number of Shifts per day.
For example, if your factory operates with 50 worker in a specific production
line for 8 hours per shift with two shifts per day then_
Available minutes pf that line, 50×8×60×2 = 48000 minutes per day
2. Determine the SAM for Each Garment
Style:
Every garment style (shirt, pants, jacket, etc.) will have a specific SAM
value, which represents the time required to complete one unit of that garment.
These values can be determined through time and motion studies or are sometimes
provided by garment manufacturers. For instance, if the SAM for producing a
Shirt is 22 minutes, it means a worker is expected to take 22 minutes to make
one Shirt under normal conditions.
3. Calculate the Production Capacity:
To determine how many units can be produced in a day, divide the available
minutes by the SAM:
Therefore,
Daily Production Target = Daily Available Minutes / SAM per unit garment
For example, if the SAM for a Shirt is 22 minutes:
Daily Production Target = 48000 minutes
/ 22 minutes per unit = 2181 Shirts
per day
4. Adjust for Efficiency and Workforce
Variability:
Typically, a factory may not operate at 100% efficiency due to variability in
the workforce, machine downtimes, etc. Therefore, you have to apply an
efficiency factor (e.g., 70%) to the target:
Adjusted Daily Target = Daily Production Target × Efficiency %
If the efficiency factor is 70%, then:
2181× 70 / 100% = 1526 pcs Shirts per day (rounded to 1500 units)
Setting Targets Using Cycle Time
Cycle Time is the actual time it takes for a machine or operator to produce one
unit, measured from start to finish. It can vary from the SAM if actual
performance deviates from the standard time (due to factors like machine speed,
skill levels, etc.).
Steps to Set Daily Production Targets
Using Cycle Time:
1. Calculate the Daily Available Time:
As with SAM, first calculate the total available working time for the day. For
example, if your factory operates 8 hours per shift with 2 shifts, the
available time will be:
8×60×2=960 minutes per
day
2. Measure the Cycle Time for Each
Process:
Cycle time varies across different processes (e.g., cutting, stitching,
finishing). Measure the time it takes to complete one cycle (one unit). This
can be done through direct observation or from historical data. For example, if
the cycle time for stitching one Shirt is 25 minutes, you know that it takes 25
minutes to complete the stitching phase of the production.
3. Calculate the Daily Production
Target:
The formula for calculating daily production using cycle time is similar to
SAM:
Daily Production Target = Daily Available Minutes / Cycle Time per Unit
If the cycle time for a Shirt is 25 minutes:
Daily Production Target = 960 minutes
/ 25 minutes per unit = 38.4 Shirts
per day (rounded to 38 units)
4. Adjust for Downtime and Efficiency:
Similar to SAM, you must consider potential downtime (for maintenance, breaks,
etc.) and efficiency factors. If your efficiency is 85%, then:
38 × 0.85=32.3 Shirts per day
(rounded to 32 units)
Comparison Between SAM and Cycle Time:
SAM is a standard time that reflects the expected time to complete a task,
considering allowances for rest, delays, and inefficiencies. It is based on
established standards and often used for long-term planning and budgeting.
Cycle Time reflects the actual time taken to complete a unit, which may differ
from the SAM due to real-world factors like machine speed, operator skill, or
process inefficiencies. Cycle time is more accurate for short-term adjustments
and reflects real-time performance.
Final Considerations:
Adjust for Complexity: If you have different garment styles with varying complexities, ensure that you calculate different targets for each style.
Monitor Continuously: Continuously monitor performance against targets to adjust as needed for changes in efficiency or process improvements.
Use Both Metrics: Often, a combination of both SAM and Cycle Time can give a more accurate production target by comparing theoretical (SAM) vs. actual (Cycle Time) performance and fine-tuning processes accordingly.
In summary, SAM is useful for setting initial, theoretical targets based on standards, while Cycle Time provides a more dynamic, real-time measure of actual production performance. Both methods are important for managing and improving production efficiency in apparel manufacturing.
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