Yes, it is possible. Estimated garment production can be calculated using a formula and considering the required variables. In a sewing line, we set up a number of workstations with sewing machines and other equipment. We assign operators and helpers to make the garment. So we know the availability of the resources. We know the standard time of the garments that are running on the sewing lines. We know the efficiency of the line and the learning curve. These details are enough to calculate the estimated production of the floor.
Though it is the engineer's job to estimate garment production, anyone can learn the method of daily garment production calculation. This is the basic requirement for production management, and each person working in production must know how to estimate daily production in a garment factory.
I explained the calculation procedure for estimating daily garment production. Let's learn it.
I explained the calculation procedure for estimating daily garment production. Let's learn it.
Production is the total number of garments made by operators in a line. Production is also termed daily line output. Daily production is measured in garment units (pieces), or in dozens. To estimate production, we need the following information.
- Standard allowed minutes (SAM) of the garment
- Number of operators assigned to the line
- Plant Shift hour (if OT is planned include OT hours)
- Line efficiency level according to the learning curve
- Total break time for lunch and tea break (if any).
The formula for production estimation:
We will use the following formula to calculate daily production.
Daily Production = (Total available minutes/SAM) x Line Efficiency%
Total available man-minutes =(Total No. of operators x Working hours in a day x 60)
Let's assume that Line B is loaded with a woven blouse style. The following are the required variables:
- Garment SAM - 20 minutes
- Total number of operators working in a line - 30
- Shift hours in a day - 8 hours (excluding break hours)
- Overall Line efficiency - 50 % (in the given day)
Total available man-minutes = (30 x 8 x 60 )= 14400 minutes (240 Hours)
Using the above formula, daily estimated production
= (Total available minutes /Garment SAM) x Efficiency%
= (14,400/20) x 50%
= 360 garment units
You can expect 360 blouses (production) from Line B. The estimated production quantity will differ if we change any of the above variables.
The daily production quantity from a line is directly proportional to its efficiency, the number of operators, and working hours. Production is also reverse proportional to the garment SAM. If a line's efficiency increases, you can expect higher production.
Similarly, if the SAM of style reduces, you can expect higher output.
The daily production quantity from a line is directly proportional to its efficiency, the number of operators, and working hours. Production is also reverse proportional to the garment SAM. If a line's efficiency increases, you can expect higher production.
Similarly, if the SAM of style reduces, you can expect higher output.
If your sewing floor has 10 sewing lines, calculate the daily estimated production of each line and then sum up the line-wise quantity to derive the sewing floor production. An example of daily estimated production data is shown in the following table.
Factors that affect the daily production volume:
Any of the following non-productive measures can reduce the assembly line's production. So, to get the estimated output, you have to address the following areas.- Machine breakdown
- Imbalanced line (WIP control)
- No feeding of cuttings
- Quality problems
- Low operator performance
- Operator absenteeism
Conclusion:
The daily production target and the daily estimated production calculation method are the same with slight variations in using the efficiency data. In production target calculation, we use target efficiency for the day. We can keep this target efficiency as maximum as 100% for giving a target to the line supervisor. In target production calculation, we also consider employee absenteeism percentage. But when we actually know the operator number in the morning after the line starts working, we don't need to consider absenteeism.
Related Articles:
- What is the Learning Curve in Apparel Manufacturing?
- Relation Between Order Quantity and Line Efficiency in Garment Production
- Style Completion Report for Apparel Manufacturers