Tuesday, January 31, 2017

How to Estimate Garment Production in Apparel Industry

Garment production calculation is very important task for production manager in respective units in manufacturing. It plays an important role to the buyer for selecting right vendor for their orders. Before ordering they want to know about production capacity of factory. Besides, marketing and planning personnel should aware about the production capacity of their production units. In this article I will explain that how to calculate production of a garment factory

Production in apparel industry
Fig: Production in apparel industry
Production means total number of garment pieces produced by operators in a line or batch in a given time. Production is also termed as daily output. Production capacity of a factory 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.

How to Calculate Garment Production:
Following information also essential to estimate production in a factory:
  1. Standard allowed minutes (SAM) of the garment. It means how much time is required to make one complete garment including allowances.
  2. How many operators are working in each line?
  3. Numbers of total machine.
  4. Machine capacity.
  5. How many hours each line will work in a day?
  6. Average line efficiency level.
  7. Total break time.
Useful formula for garment production calculation:
Following formula is used for production estimation:

Daily production = Total man minutes available in a day/SAM X average line efficiency.

Total available man minutes = Total No. of operators X working hours in a day X 60.

Example: SAM of a particular garment is 20 min, with 50 operators line, which works 8hr shift in a day. Line works at an average efficiency of 50%. Operators are given a total 45 min for lunch and tea break. Now calculate the monthly production of the factory.

So, total available man minutes = 50 X (8 x 60 - 45) = 21,750 min.

Daily estimated production = 21,750/20 X 50% = 543 pieces.

Monthly estimated production = 543 X 30 = 16,290 pieces

Above output from that line is achievable if everything goes well. It can be seen that the production of a line is directly proportional to the line efficiency, number of operators, and working hours. Production is inversely proportional to the garment SAM. If efficiency of a line increases higher production can be achieved. Similarly, if the SAM of a style is reduced, then higher output can also be achieved.

Factors that Affect Garment Production:
There are some key factors, which influence to reduce the garments production. Any one of the following factors can decrease production of the assembly line. For an estimated output, the following factors should be considered.
  1. Machine breakdown
  2. Machine stoppage
  3. Imbalance line
  4. Lack of lay-out planning
  5. Continuous feeding to the line
  6. Quality problems
  7. Individual operator performance level
  8. Operator absence
Sources: Garment Manufacturing Technology by Rajkishore Nayak Rajiv Padhye