Estimated Garments Production is the total number of garments stitched by operators in a line in a day. Production is also termed as daily output. To estimate production, you need the following information.
2. How many operators are working in the line?
3. How many hours line will work in a day?
4. Average Line efficiency level?
5. Total break time for lunch and tea break (if any).
The formula for production estimation
Daily production = (Total man minutes available in a day/SAM) * Average Line efficiency
Total available man-minutes =(Total no. of operators * Working hours in a day * 60)
Let's assume
· Garment SAM is 20 minutes,
· Number of operators is 30
· Shift hours in a day = 8 hours
· Average line efficiency =50
· Operators get a total of 45 minutes for lunch and tea breaks.
So, Total available man minutes = 30 *( (8 * 60) – 45) )= 13050 minutes
Daily estimated production = 13050 /20 * 50% = 326 pieces
You can expect this much output from that line if everything goes well. Daily production quantity from a line is directly proportional to the line efficiency; the number of operators and working hours. And production is reverse proportional to the garment SAM. If the efficiency of a line increases you can expect higher production. Similarly, if SAM of style reduces at that also you can expect higher output.
Factors that hamper production:
Any one of the following can reduce the production of the assembly line. So to get estimated output, you have to take on the following areas.
· Machine breakdown
· Imbalance line (WIP control)
· No feeding of cuttings
· Quality problems
· Low operator performance
· Operator absenteeism
Some of these are non-productive time.
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