Category: Calculation

Efficiency Calculations for the Garment Industry

Calculation
Precision in Apparel Efficiency Calculations for the Garment Industry

Efficiency calculations pivotal to the textile trade. From fabric requirements to cost analysis, embark on a journey to master the precision needed for success in the dynamic realm of fashion manufacturing.

01. Target = 60 ÷ (SMV x No. of worker x working hour x expected efficiency).

02. Target = 60÷SMV.

03. Team target =(60÷SMV) x Present operator x Organization efficiency.

04. Target per day = Working hour x 60 x No. of operator / Target SMV.

05. Capacity=Average of total obserb time x 1.66 + 30% Allowance / 60.

06. Factory capacity=No. of operator x working minutes + Present % x average factory efficiency.

07. Capacity per day = Present operator x working hour x organization efficiency x Attendance.

08. Weekly capacity = No. of operators x Absenteesm x Clock minutes per week x Average factory efficiency.

09. Marker efficiency = Area of patterns in the marker / Total area of the marker x 100.

10. Load = (Contract size x work content) contract 1+ (Contract size x work content)

Contract 2 + etc.

11. Load = Order quantity x Work content (SMV of garments).

12. Observe time = Total cycle time / No. of cycle.

13. Basic time = Avarage of observe time X Rating %.

14. Sam = Basic time x Allowance.

15. Rating = Observe time x Standard rating / Standard rating.

16. Cycle time = 60 / Team target.

17. Pitch time = Total SMV / Present operator.

18. Efficiency = Earn hour / Available hour x 100

19. Efficiency = SMV / Total time.

20. Earn hour = (Production x SMV) / 60.

21. Available hour = Working hour x Use machine(Total manpower)

22. Performance = (Earn hour / Available hour – Off standard time) x 100.

23. Improvement = 1-(Production / Capacity).

24. Balancing efficiency = 1-Balancing loss.

25. Loss pcs = (60/SMV)x Available hours x avg factory effi (61%) -Q.C Pass

26. Balancing loss = AML-TML/AMLx100.

27. Standard time = Net operation time x (1+ Ratio of loss time).

28. Daily output = Working hours (seconds) + Standard time.

29. Output per operator = Work hours (second) / Total time of operations.

30. Required No. of operators = Targeted daily output / Daily output per operator.

31. Target daily capacity = Daily work hours / Standard process time (SPT).

32. Daily capacity per worker = Daily capacity / No. of workers = Daily Work hours / Standard total processing.

33. Organization efficiency = Pitch time / Bottle neck process time (x100) = 100/140 x 100 = 71.4%

34. Upper limit = Pitch time / Target organization efficiency = 100 / 0.85 = 117.6 seconds.

35. Lower limit = 2 x Pitch time – Upper limit = 2 x 100 – 117.6 = 82.4 seconds.

36. Planned daily work flow = Daily work hours / Standard process time (SPT) x organization efficiency.

37. Accumulated avarage time = Daily work hours/AccumulatedxNo.of daysxstandard No.of workers in

The group/No. of pieces produced.

38. SMV = Basic time + Allowance time + bundle time.

39. DHU = No. of defect observe / No. of garments checked.

39. Booking fabric K.G. = Order quantity / 12 x Fabric consumption per doz.

40. Garments K.G. = Total receive fabric kg – (Save return kg + Jhute kg + Wastage fabric kg)

40. Input to sewing pcs. = Total in pcs – (Print Embroidery short & wastage + Cutting wastage pcs.)

39. Fabric consumption (CM) = Length x chest x 2 x GSM / 1000 / 10000 x 12 + Wastage%.

41. Fabric consumption (Inch) = Length x chest x 2 x GSM / 1000 / 1550 x 12 + Wastage%

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Marker making & Marker efficiency calculation

CAD, Calculation, Cutting
Marker making & Marker efficiency calculation

Marker is used to cut too many garments pieces at a time (depend on fabric lay) in cutting section. There are a few important matter need to follow carefully during making and during using the marker like marker efficiency, A minor mistake can be the reason to wastage of huge fabric, material and man-power. Most of the time all of those lead by cutting supervisor and coordinator.  Fabric layer operator also responsible to do such things and maintain the standard. Let’s go through the matter which is important to follow carefully. Please don’t skip any of those option to avoid misconceptions.

Marker making & it’s efficiency calculation- Indication

You better check each marking on above picture to understand clearly.

1. Marker Name

Every marker has a unique name which provide the style of the marker made from or made for. Doesn’t clear?  Name of the marker indicate the style, cutting number, production status and fabric width. Depend on the company policy the name of marker can be changes as per their rule, regulations and needs.

  • The cutting status of the particular style (Is it Size Set, Pilot or bulk cutting).    
  • Type of garments (Top, Bottom, Bra, panty, shorty, Tanga, Boxer, Etc)
  • Cutting number (which number of cutting required this marker to complete cut).
  • PO number (Product order Number)
  • Make marker base on fabric Actual cut-able Width (This is marker width)

You like this https://www.textilestudent.com/marker-making-and-using-technique-of-marker/

2. Marker Length

After complete the marker its takes a length. The length means the actual length of the fabric lay should be makes to cut the cutting. Cutting super visor starts making lays by layer man according the marker length.

3. Ratio

I hope you know the meaning of “ratio”. It’s indicate the variation on different size quantity in a marker. Suppose I’m going to make a marker from XS-XL where I need the make ratio according to my PO quantity.

Like this,

XS—S—M—L—XL

1—-2—-1—3—1

Marker making & it's efficiency calculation
Marker making & it’s efficiency calculation

4. Actual fabric width / Marker width

Part of garments need to place in marker where the actual fabric width should be measure by responsible person. They measure the fabric width and make Job Card and send to CAD department to make marker. Job card can be named layer Sheet, Cutting Plan, Cutting Sheet, Cutting Production Plan and many more name. The name always depends on the production environment of any factory.

5. Unplaced / Placed pieces

Total Pieces of current marker show here and let us know how many pieces are placed and unplaced.

6. Utilization or Marker Efficiency. 

This is so much serious matter, most of the company constantly monitor this matter. Because maximum utilization means maximum fabric usages. If you are making marker you should have follow this matter to reduce the wastage.

When we do costing consumption; it’s important to check which fabric width is better for costing. Then we try to make marker by various fabric width. Question is how find out which width is perfect?
Perfect width decided by comparing the utilization of different width.

Did I miss something to include in this marker? If yes then you replay on comment box or write me by this mail info@textilestudent.com

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Calculation of fabric manufacturing

Calculation
Calculation of fabric manufacturing

Fabric manufacturing needs a full proof calculation to make a better profit. Every production manager always does calculation to reduce the wastage and make larger profit. Calculation can help to make a cheaper deal with buyer as no one able to do. In this following article I’m going to show you some critical calculation formula which is important to know every textile professional, textile engineer, Professor even a textile student.

Calculation of fabric manufacturing

Calculation of fabric manufacturing

Technical Formula

                                                     Motor pulley diameter
Loom speed = Motor RPM x ——————————-
                                                      Loom pulley diameter

                                               Actual production
Loom Efficiency % = ——————————-x 100
                                          Calculated production

                                           Yarn weight – Dried yarn weight
Moisture Regain % = ——————————————— x 100
                                                       Dried yarn weight

                                              Yarn weight – dried yarn weight
Moisture Content % = ———————————————— x 100
                                                               Yarn weight

                                             Total ends x Tape length in meter
Warp weight in Kg. = ——————————————————
                                                       1693.6 x Warp count

                                      RS in centimeters x Cloth length in meters x PPI
Weft weight in Kg. = ——————————————————————
                                                              4301.14 x Weft count

                                                    EPI                  PPI
Cloth weight in GSM = —————– + —————– x 25.6
                                               Warp count      Weft count

                                              GSM (Grams per sq. meter)
Oz (Ounce) per sq. yard = ——————————————
                                                                        34

Mathematical formula

Total wt. of size on warp = wt. of sized warp – wt. of upsized warp.

The wt. of size to be put on warp = wt. of upsized warp x % of size reqd to be put on warp.

                                            Length of warp in yds
the wt. of upsized warp = ——————————- x no. of ends + wt. of size.
                                                       840 x count

                                                Wt. of size
Wt. of sized warp = —————————— x 100%
                                      Wt. of upsized warp

                                                 Wt. of size
% of size on warp = —————————– x 100%
                                         Wt. of upsized warp

                                                   length of warp in yds
Count of sized yarn = ——————————————- x no. of ends
840 x wt. of sized warp (in lbs)

                                                                                      100
Count of sized yarn = count of upsized yarn x ———————–                                                                                100 + % of size

You may interested to read Terms of fabric Manufacturing and GSM Calculation

If any you have doubt or if you have any complain about this theory or information please let me know by posting a comment. Don’t be hesitates to ask!

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