Defining Efficiency and Performance In terms of general definitions: Performance is the degree to which a system or machine achieves its objective. The amount of resources utilized to achieve a goal is measured by efficiency.
How to Differentiate the Efficiency and Performance in Garments Industry |Textile floor|
Defining Efficiency and Performance In terms of general definitions: Performance is the degree to which a system or machine achieves its objective. The amount of resources utilized to achieve a goal is measured by efficiency.
Industrial Production Engineering in Garments │Textile Floor│
1. Basics of Industrial Engineering in Apparel Production
- What is Industrial Engineering in Garment
Manufacturing?
- Role of Industrial Engineers in Garment
Production Management
- Standardization of Operations in Garment Making
- Work Study and Industrial Engineering Terms
and Definitions
- What is the Difference between Performance and
Efficiency?
- How to Differentiate the Efficiency and Performance in Garments Industry
- Overall Efficiency Vs On-Standard Efficiency
- Productivity Improvement Strategies in the
Apparel Industry
- Major Factors Affecting Factory Efficiency
- First Step for Improving Factory Efficiency
How to calculate Garment SAM or SMV │Textile Floor│
30 Proven Ways to Boost Productivity in Garment Manufacturing and Maximize Profit │Textile Floor│
TMU (Time Measurement Unit) and Its Application in Garment Manufacturing │Textile Floor│
What is TMU?
TMU, or Time Measurement Unit, is a standard unit of time used to measure and analyze work in industrial engineering. It is primarily used in methods-time measurement (MTM) systems for assessing and standardizing manual operations.
It is a small unit of time used in the Methods-Time Measurement (MTM) system. This system assigns a predetermined amount of time to basic motions, such as reaching, grasping, or moving an object, based on their complexity and effort required.
How to Reduce Standard Time (SAM) for Garment Production Styles │Textile Floor│
Conduct Motion Study
Identify and eliminate unnecessary motions during sewing operations. Optimise operator movements to reduce operation cycle time. Do Method Study or analyse the operation to record the motion, motion sequence and required time needed for those each motions, re-sequence, eliminate and rearrange the motion therefore do and adjust anything from the findings in your analysing to reduce the process time actually.
2.
Use Work
Aids and Attachments
Incorporate folders, guides, and attachments to simplify operations and minimize
manual adjustments, reducing the time required for stitching.
3.
Adopt
Automation
Use automated machines such as auto-trimmers, computerized sewing machines, and
robotic cutters to complete repetitive tasks more quickly and accurately.
4.
Optimize
Line Balancing
Balance the sewing line by aligning task assignments with operator skills to
ensure smooth workflow and avoid bottlenecks from first to last process which
can be the great to gain exact Target.
5.
Redesign
Garment Construction
Modify garment construction to simplify complex operations without compromising
design or quality. For example, replace multiple seams with a single stitch
line but remember about the required strength of the joining.
6.
Improve
Workstation Layout
Design ergonomic workstations with components placed within easy reach,
reducing handling time and operator fatigue, less quantity gathering in hand.
Here we can use 5S method also in every workstation which influences to
minimize the process time.
7.
Implement
Modular Production
Use modular layouts for complex garment styles to divide operations into
smaller, manageable sections for faster assembly.
8.
Streamline
Cutting and Marking
Ensure precision in fabric cutting and marking to eliminate the need for
post-sewing corrections, reducing wasted time.
9.
Pre-plan
Operations
Use operation bulletins and Standard Operating Procedures (SOPs) to streamline
workflow, ensuring operators know exactly how to perform each task. Supervisor
must maintain and follow the Operation Bulletin.
10.
Train
Operators
Provide task-specific training to enhance operator efficiency, enabling them to
complete operations faster with fewer errors.
11.
Use Lean
Manufacturing Techniques
Apply lean principles such as value stream mapping to identify and eliminate
non-value-adding activities in production.
12.
Optimize
Thread and Needle Selection
Choose the right thread and needle combinations to reduce thread breakage and
improve stitching speed.
13.
Minimize
Handling Time
Reduce the number of times a garment is handled during production by
grouping tasks or using automated material handling systems.
14.
Perform
Real-Time Monitoring
Implement real-time tracking systems to identify inefficiencies and
bottlenecks, allowing for immediate corrective actions.
15.
Improve
Quality at the Source
Use inline quality checks to catch defects early, avoiding rework that
increases production time.
16.
Simplify
Styles during Design Phase
Collaborate with designers to create styles that are easier and faster to
produce without compromising aesthetics.
17.
Use
High-Efficiency Equipment
Replace outdated machinery with modern, high-speed machines to increase
output and reduce cycle times.
18.
Standardize
Processes
Establish standardized methods for recurring operations to ensure
consistency and minimize variability.
19.
Implement
Continuous Feeding Systems
Ensure a steady supply of materials to sewing lines to prevent idle time
and maintain production flow.
20.
Analyze
Historical Data
Review past production data to identify best practices for reducing
standard times in similar garment styles.
By implementing these techniques, garment manufacturers can significantly reduce SAM, improve productivity, and enhance overall operational efficiency.
Why Determining SAM from Garment Images is difficult │Textile Floor│
Determining the Standard Allowed Minutes (SAM) from garment images presents several challenges. SAM is a crucial metric in the garment manufacturing industry, used to determine the standard time required to produce a garment. However, extracting this information from images, especially automated systems, faces multiple hurdles. These challenges include:
1. Complexity of Garment Features
Style Changeover Time (COT) in Garment Manufacturing │Textile Floor│
In garment manufacturing, one of the most critical yet often overlooked factors affecting overall productivity is Style Changeover Time (COT). This term refers to the period between the last piece of the previous style coming off the production line and the first piece of the new style being produced. Ideally, this changeover time should be as short as possible to minimize downtime, increase machine utilization, and maintain production flow. A prolonged COT not only hampers productivity but also increases costs and delays customer orders.
How to Set Accurate Sewing Operation Rates in the Garment Industry │Textile Floor│
In garment production system, one of the most critical and difficult tasks is to determine the right rate for each sewing operation. This is often done on a "piece-rate" basis, where workers are paid as per the number of garments they can make, or the number of specific sewing operations they complete. However, setting a fair and accurate rate involves more than just a guess. In this writting, we’ll explore how to calculate the individual operation rates, with a focus on scientific methods, and discuss the factors that influence the pricing of different sewing tasks.
What Are Sewing Operation Rates?
Sewing operation rates refer to the payment made to workers for completing specific sewing tasks, such as attaching a shoulder, sewing a neck rib, or attaching sleeves. These rates are crucial because they directly affect workers' earnings and the overall production cost of a garment. In most garment factories, different operations are priced differently based on the complexity and time required for each task.
Key Factors Affecting Operation Rates
To calculate the operation rates for various sewing tasks, several factors need to be taken into account:
1. Standard Allowed Minutes (SAM)
SAM is a unit used to determine the time required to complete a particular operation under normal working conditions. SAM values are determined based on industrial engineering studies or by using historical data from similar operations.
For example, if attaching a sleeve takes 4 minutes, the SAM for that operation would be 4 minutes.
2. Operator Capacity
The operator's capacity refers to the number of pieces a worker can produce in a given time, usually per hour or per day. This capacity is influenced by the worker's skill level, experience, and the machine or equipment used.
For example, an experienced operator may attach 25 pieces per hour, while a less experienced operator may only complete 20 pieces.
3. Wages and Hourly Rate
The wage rate of operators plays a critical role in determining the rate for each sewing operation. This involves calculating the worker’s hourly wage and per-minute wage, based on the minimum daily wage standards set by the factory or the local labor laws.
For example, if an operator earns Rs. 60 per hour, the per-minute rate would be Rs. 1 (Rs. 60 divided by 60 minutes).
4. Machine Efficiency and Maintenance
The type of machines used, their maintenance status, and their efficiency also influence the time taken for each operation. Well-maintained, high-efficiency machines can reduce the time required to complete an operation, which in turn lowers the operation rate.
5. Type of Garment
The complexity of the garment being produced plays a significant role in determining the rate for each operation. For instance, a basic T-shirt may have simpler operations than a more complex, multi-layered jacket or a knitted garment.
6. Production Environment
The overall working conditions, including the work environment, lighting, and ergonomics, can also impact operator efficiency and the time required for each task.
The Process of Calculating Sewing Operation Rates
To calculate an operation rate, you can follow these steps:
Step 1: Determine the
SAM for the Operation
Each operation (e.g., shoulder attach, sleeve attach, etc.) has a predetermined SAM based on the time it takes for a skilled operator to complete that task under normal conditions. SAM values can be found in sewing operation charts, provided by industrial engineering teams, or established through time studies.
Step 2: Calculate the
Operator’s Per-Minute Rate
To calculate this, divide the operator's hourly wage by 60 (to get the per-minute rate).
For example, if an operator earns Rs. 60 per hour, the per-minute rate would be Rs. 1.
Step 3: Calculate the
Operation Rate
The formula for calculating the operation rate is:
Operation Rate=SAM×Rate per Minute\text{Operation Rate} = \text{SAM} \times \text{Rate per Minute}Operation Rate=SAM×Rate per Minute
For example, if the SAM for attaching a sleeve is 3 minutes, and the operator’s rate per minute is Rs. 1, the rate for attaching the sleeve would be:
Operation Rate=3×1=Rs.3\text{Operation Rate} = 3 \times 1 = Rs. 3Operation Rate=3×1=Rs.3
Step 4: Calculate the
Total Daily Earnings for the Operator
To estimate how much an operator will earn per day, multiply the operation rate by the number of pieces an operator can produce in a day.
Let’s assume the operator can complete 200 pieces in a day, and the operation rate for attaching sleeves is Rs. 3. The total earnings for that operation would be:
Daily Earnings=200×3=Rs.600\text{Daily Earnings} = 200 \times 3 = Rs. 600Daily Earnings=200×3=Rs.600
Example of Calculating Operation Rates
Let’s break down an example for a few common garment operations:
Operation: Shoulder Attach
SAM: 5 minutes
Operator’s hourly rate: Rs. 50
Per-minute rate: Rs. 50 ÷ 60 = Rs. 0.83
Operation rate = 5 minutes × Rs. 0.83 = Rs. 4.15
Operation: Sleeve Attach
SAM: 4 minutes
Operator’s hourly rate: Rs. 60
Per-minute rate: Rs. 60 ÷ 60 = Rs. 1
Operation rate = 4 minutes × Rs. 1 = Rs. 4
Operation: Neck Rib Attach
SAM: 3 minutes
Operator’s hourly rate: Rs. 55
Per-minute rate: Rs. 55 ÷ 60 = Rs. 0.92
Operation rate = 3 minutes × Rs. 0.92 = Rs. 2.76
In this case, the operator can earn Rs. 4.15 for shoulder attach, Rs. 4 for sleeve attach, and Rs. 2.76 for neck rib attach, depending on the specific garment being produced and the operations involved.
Conclusion
Understanding how to calculate the individual sewing operation rates in garment production is crucial for both manufacturers and workers. It ensures fair compensation for workers, while helping factories maintain cost control and optimize production. By thinking factors like SAM, operator capacity, wages, and machine efficiency, you can determine the most accurate and fair operation rates. This not only helps in setting up a productive and cost-effective factory but also ensures a transparent and equitable system for piece-rate workers.
By applying the right formulas and methods, you can make data based decisions to improve your garment production process and ensure that workers are compensated based on the time and effort needed to complete their tasks.
How to Set Daily Production Targets Using SAM vs. Cycle Time in Apparel Manufacturing │Textile Floor│
Setting daily production targets in apparel manufacturing involves evaluating both Standard Allowed Minutes (SAM) and Cycle Time. These two metrics are critical for determining how efficiently a factory can produce garments. Here’s how you can set daily production targets using each of these methods:
1. 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:
Calculate the Daily Available Minutes:
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:For example, if your factory operates 8 hours per shift with two shifts per day:
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 T-shirt is 20 minutes, it means a worker is expected to take 20 minutes to make one T-shirt under normal conditions.Calculate the Production Capacity:
To determine how many units can be produced in a day, divide the available minutes by the SAM:For example, if the SAM for a T-shirt is 20 minutes:
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 may apply an efficiency factor (e.g., 85%) to the target:If the efficiency factor is 85%, then:
Consider the Number of Workers or Machines:
If you have multiple workers or machines, you can adjust the target based on available resources. For example, if you have 5 sewing machines or workers, the total daily production target can be divided across all workers:
2. 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:
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: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 T-shirt is 25 minutes, you know that it takes 25 minutes to complete the stitching phase of the production.Calculate the Daily Production Target:
The formula for calculating daily production using cycle time is similar to SAM:If the cycle time for a T-shirt is 25 minutes:
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:Factor in the Number of Workers or Machines:
If you have multiple workers or machines, divide the daily production target across them to determine how many units each worker or machine should produce.
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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