Capacity in apparel industry

It is calculated simply by the amount of machines available and hours per day determined to work to be realistic ,one has to determine the efficiency level of the operators and incorpor

© SOFT Student Handouts,

By, Sunil Talekar, Faculty, SOFT-Pune

SunilTalekar

Following part are involve while Garment

APPAREL ENGINEERING CONCEPTS

 METHOD STUDY

The in depth monitoring and analysis of the way an operator performs its task is called method study.

Three to four method study will guide you to select the right method

to perform any operation and the we can proceed for next operation as well to find out the causes of delay in the process of stitching.

Once the method study is done, one looks for better ways to save time and less effort by the operator This could be done by improving work motions / provide work aids like gauges , folders , attachments , trolleys , movers, tracks or machine automation.

APPAREL ENGINEERING CONCEPTS

 TIM E STUDY

The recording of time of every motion conducted by the operator is termed as time study Once the time is recorded, allowances for fatigue, machine delays , personal breaks and various times are integrated into the pure time to derive real time This time is termed as SAM ( Standard Allowed M inutes) of SM V ( Standard M inute Value ).

Time study will guide us to calculate the standard minutes for any specific operation and it is the average for one cycle of an operation that

we would measure over a typical day if we had;

1 A skilled operators

2 Plenty of works

3 Workplace and machinery

4 Output with correct level of quality

5 Less weakness

6 Expected delays due to process

Exercise: sewing machine threading exercise, to calculate SM in SOFT

APPAREL ENGINEERING CONCEPTS

 IDLE TIM E

During the course of production, it is observed that operators are idle and wait for production buildup to make them go into motion, this idle time is loss of time and production

 CREATIVE PRODUCTION PLANNING

Creative production planning is use of various techniques to assure that idle time is less or eliminated more production in less time is key to success for any manufacturing plant

APPAREL ENGIEERING CONCEPTS

 FACTORY PRODUCTION CAPACITY

Factory production capacity is derived from the resources available at the manufacturing plant It is calculated simply by the amount of machines available and hours per day determined to work

to be realistic ,one has to determine the efficiency level of the operators and incorporate the percentage to derive actual capacity.

Example : if a factory has 100 machines and working hours are 8 hours per day and 26 days per month the efficiency level of operators is observed to be at 80% the production capacity available time per month would be calculated as below :

Available monthly production time capacity :

100 machines x 480 M ins x 80 / 100 = 38400 M ins / day.

38400 M ins x 26 days = 998400 M ins /month or 16640 hours/month.

APPAREL ENGINEERING CONCEPTS

 SPECIAL MACHINE PRODUCTION CAPACITY

Once planning production , it has to be known that if any special operation is required within the garment which require special machine or machines if so , the output capacity for those garments have to based upon special machine production the management can then decide if those machines be worked overtime or if required

to meet shipment date , additional machines be purchased

To calculate special machine capacity per month , the available machines are 10 , work hours /day are 8 hours , efficiency level is 80% and working days per month is 26 days

Special production capacity in time / month =

10 machines x 480 M ins x 80 / 100 = 3840 M ins / day

3840 M ins x 26 days = 99840 M ins / month or 1664 hours /month.

APPAREL ENGINEERING CONCEPTS

 AVAILABLE CAPACITY :

Difference between potential capacity and committed capacity for a certain time period

 REQUIRED CAPACITY :

Sam or SAH necessary to produce a specified volume

in a certain time period

 EXCESS CAPACITY :

Difference between potential capacity and required capacity

PRODUCTION CAPACITY

Lets say ABC garments company has 20 operators who work 8 hours a day The plant has 90% efficiency level Working shift is 8 hours a day in which 1 hour is mainly for lunch and tea time break.

So their potential capacity for next 10 days will be,

20 machines x 7 hours /day = 140 hours/day x 90% efficiency = 126 potential

production hours /day.

Potential capacity for 10 days = 10 days x 126 hours = 1260 hours potential capacity.

EXERCISE TO UNDERSTAND

RELATIONSHIP OF CAPACITY TERMS.

EXERCISE TO UNDERSTAND

RELATIONSHIP OF CAPACITY TERMS.

A Sale brings in order for 10000 units of style “ax” that needs to be delivered in

10 days the plant already has a committed capacity of 600 hours for the 10 days period It was established that style “ a” has a production time of 5 SAM

So their required capacity for 10000 units will be;

5 SAM /unit x 10000 units = 50,000 SAM or 833 SAH to complete the order Capacity required = 833 hours

What is available capacity in the plant currently ?

Ans Available capacity = potential capacity – committed

capacity

Available capacity = 1260 hours – 600 hours = 660 hours available

Lets say ABC garments company has 10 operators who work 8 hours a day The plant has 90% efficiency level A customer brings in order for 6000 units of style “a” that needs to be delivered in 10 days the plant already has a committed capacity of 300 hours for the 10 days period.

Working shift is 8 hours a day in which 1 hour is mainly for lunch and tea time break

It was established that style “ a” has a production time

of 5 SAM The order of 6000 units require 30,000 SAM ( 500 hours ) What factors should be considered in deciding whether to accept the order or refuse?

EXERCISE TO UNDERSTAND

RELATIONSHIP OF CAPACITY TERMS.

What is the potential capacity of united garments company for the 10 working days ?

Ans 10 machines x 7 hours /day = 70 hours/day x 90% efficiency = 63 potential

production hours /day.

Potential capacity for 10 days = 10 days x 63 hours = 630 hours potential capacity.

What is required capacity for the 6000 unit order ?

Ans 5 SAM /unit x 6000 units = 30,000 SAM or 500 SAH to complete the order

Capacity required = 500 hours.

What is available capacity in the plant currently ?

Ans Available capacity = potential capacity – committed capacity

Available capacity = 630 hours – 300 hours = 330 hours available

Is available capacity adequate to accept the order ?

Ans 330 hours of available capacity – 500 hours of required capacity = -170 hours

Capacity is not sufficient to accept order

 Require more time from buyer to accommodate the 170

hours

 Work overtime to cover the 170 hours

 Increase more machines and operators

 Find way to increase efficiency level to 100 %

 Use creative production technique to increase

productivity

 Try to eliminate idle time within production to decrease

throughput time

 Assess the performance of individual operators.

WHAT ADJUSTMENT HAS TO BE MADE TO

ACCOMMODATE THE ORDER IN HAND ?

 Estimate the rate or time for completion of each

operation.

 Determine the required capacity for an order or style.

 Determine the production start dates and completion

dates for orders.

 Plan the daily volume that should have been completed.

 Determine the backup inventory needed to support the

work flow.

 Determine how many operaqtors and machines should be

performing on each operation.

 Schedule specialized equipment

 M onitor daily production delays.

PRODUCTION STANDARDS ARE USED IN

PRODUCTION PLANNING TO DO THE FOLLOWING :

QUESTION ONE.

Plant capacity is :

 A projection of the total hours available for production in a given time period.

 N umber of garments a plant can produce in a certain time period

 N umber of machines available to meet the capacity of orders

Committed capacity is :

 The orders which P.O Still not received

 Orders waiting for confirmation

 Total hours previously allocated for production in certain time

Available capacity is :

 The volume which can be still produced in a plant

 The styles which orders can be taken and ship on time

 The difference between plant capacity and committed capacity for a certain time period

If a garment has Sam = 6 min the plant capacity is 4800 min/day efficiency of plant at 100% how many days will it take to produce 12000 garments ? how many machines does the plant own ?

QUESTION TWO

What will be plant potential capacity ? If the plant has:

 125 machines

 6 working hours / day

 5 working days / week

 Efficiency level 80%

Answer : Plant capacity / day: _

Plant capacity / week:

QUESTION THREE.

What will be the required order capacity ? If the order details are :

 Order quantity : 30,000 garments

 Sam / garment = 15 M ins

Answer : Required capacity total hours :

Days required to complete order: _

QUIZ

Product description :

Fleece top L/S with neck band / cuff & w Band all sewn on over lock machines

Fill in blanks 8 hours work time /day 26days/month 100% efficiency.

Op no Operation Sam Prod/day M achine type M achine qty

 B-Total machines required to produce 320 garments/day? _

 C-How many days required to produce 2880 garments? _

 D- how many machines required to produce 24,000 in 20 days? QUESTION FOUR GARMENT BREAKDOWN SHEET

Equipment requirement : O/L = 19

Production output target = 1000 units per day Indirect labor: Operation SAM Prod/day M anpower Req

1-Turn cuff(2) 0.50 960 1

2-Turn Col 0.37 1297 1

3-Turn W Band 0 40 1200 1

Productivity increase: 8.567 – 7.290 = 1.277 / 8.567 = 15 %

Separating indirect labor resulted into :

 15% productivity increase 1000+150 = 1150 output

 19 machines-16 machines = 3 less machines

 Indirect labor cost ½ the operator cost saved.

 3 machines less inline less space.

 3 less machine machine cost saved

Quiz ( Answer Sheet )

Question one.

Plant capacity is :

 Projection of the total hours available for production in a given time period.

 Number of garments a plant can produce in a certain time period

 Number of machines available to meet the capacity of orders

Committed capacity is :

 The orders which P.O Still not received

 Orders waiting for confirmation

 Total hours previously allocated for production in certain time

Available capacity is :

 The volume which can be still produced in a plant

 The styles which orders can be taken and ship on time

 The difference between plant capacity and committed capacity for a certain time period

If a garment has Sam = 6 min the plant capacity is 4800 min/day efficiency of plant at 100% how many days will it take to produce 12000 garments ? how many machines does the plant own ?

 10 days 10 machines

 2.5 days 20 machines

 5 days 40 machines

 15 days 10 machines

 QUESTION TWO

WHAT WILL BE PLAN T POTEN TIAL CAPACITY IN SAH’S ? IF THE PLAN T HAS:

 125 M ACHIN ES

 6 WORKIN G HOURS / DAY

 5 WORKIN G DAYS / WEEK

 EFFICIEN CY LEVEL 80%

AN SWER : PLAN T CAPACITY / DAY:_125 X 6HR X80%= 600 HRS

PLAN T CAPACITY / WEEK: 600 HRS X 5 = 3000 HRS

 QUESTION THREE.

WHAT WILL BE THE REQUIRED ORDER CAPACITY ? IF THE ORDER DETAILS ARE

 ORDER QUAN TITY : 30,000 GARM EN TS

 SAM / GARM EN T = 15 M IN S

AN SWER : REQUIRED CAPACITY TOTAL H OURS : 30,000 X 15 SAM /PC / 60 = 7500 H RS

DAYS REQUIRED TO COM PLETE ORDER: 7500 H RS

- = 12.5 DAYS

600 H RS/DAY

2 Close/set n.Band 4.50 106 O/L 3

3 Set sleeve 3.00 160 O/L 2

4 Close side 1.50 320 O/L 1

5 Close/set cuff 6.00 80 O/L 4

6 Close/set w.Band 3.00 160 O/L 2

Answer:

A- Total Sam / garment : 16 Sam

B- Total machines required to produce 320 garments/day ? 14 machines

C- How many days required to produce 2880 garments ? 2880 / 320pcs/day=

9 days

D-How many machines required to produce 24,000 in 20 days ? ?

24,000 / 20 days = 1200 units Req./day 1200 units x 16 Sam

= 19200 Sam/ 480mins= 40 machine

THANK YOU