Application of Industrial Engineering In Apparel Manufacturing

Different Terms Used In IE:

• Work Study
• Method Study
• Time Study
• Motion Analysis
• Productivity
• KPI (key of performance Indicator)
• SMV

Calculation of  SAM/SMV:            

Steps for calculating Standard Allocated Minute( SAM) or Standard minute value(SMV) Through Time Study:

Step 1: Select one operation for which you want to calculate SAM.

Step 2: Capture cycle time for that operation by stop watch standing by side of the operator. (cycle time -total time taken to do all works needed to complete one operation). Do time study for consecutive five cycles. Calculate average of the 5 cycles. Time we get from time study is called cycle time.

Basic Time = Cycle Time X Performance rating

* Performance rating: Performance rating means at what performance level operator doing the job, considering his movement and work speed. Suppose that operator performance rating is 80%. Suppose cycle time is 0.60 minutes. Basic time = (0.60 X 80%) = 0.48 minutes

Step 3: Standard allowed minutes (SAM) = (Basic minute + Bundle allowances + machine and personal allowances). Add bundle allowances (10%) and machine and personal allowances (20%) to basic time. Now we get Standard Minute value (SMV) or SAM. SAM= (0.48+0.048+0.096) = 0.624 minutes.

Operator On-Standard Efficiency:

 Operator on-standard efficiency (%) = Total minute produced /Total on-standard minute attended *100%
Where,
Total minutes produced = Total pieces made by an operator X SAM of the operation [minutes]
Total on-standard minute attended = (Total hours worked – Loss time) x 60 [minutes]

Example:

An operator was doing an operation of SAM 0.50 minutes. In an 8 hours shift day he produces 400 pieces. Operator was idle ‘waiting for work’ for 30 minutes and his machine broke down for 15 minutes in hours shift. So according to the efficiency calculating formula, that operator’s on-standard efficiency

= (400 x 0.50) / {480 – (30 +15)}*100%
= 200/435*100%
= 45.98%

Efficiency of a Production Line:

Line efficiency = Total minutes produced by the line/total minutes attended by all operators

a. Total minutes produced by the line: To get total produced minutes multiply total production pieces by SAM
b. Total minutes attended by the all operators in the line: Multiply number of operators by daily working hours.

Minute cost of Operator:

 1. Labor cost per minute = (Monthly salary of an operators/Total minutes available in the month) at 100% efficiency.

Example:                             

Operator monthly salary is 5000.00 tk
Total available capacity per month (in minute) = 26 working days*8 hours/day*60=12,480 minutes

So, per minute cost of the direct labor = 5000/12480 = 0.4006 tk at 100% efficiency

CM cost = (SAM of the garment * Minute cost of the labor)/Line efficiency(%)

If Sewing SAM is 15 minutes and line perform at 50% efficiency then estimated garment make cost = 15*0.40/50% =12 Tk And Cutting SAM is 2 minutes and cutting room perform at 50% efficiency then estimated cutting cost = 2*0.40/50%=1.6 tk
So, Total estimated CM cost of the garment = (12.00+1.60) = 13.60 Tk
To Be Continued………..

Posted in: Garment