Capacity in apparel industry

CAPACITY

© SOFT Student Handouts,By, Sunil Talekar, Faculty, SOFT-

Pune SunilTalekar

Following part are involve while Garment Engineering;

Method study Method Improvement Time Study Idle Time Creative Production Planning Factory Production Capacity Special Machine Production Capacity

APPAREL ENGINEERING CONCEPTS

METHOD STUDYThe 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.

METHOD IMPROVEMENTOnce 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.


TIME 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 Minutes) of SMV ( Standard Minute 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 operators2. Plenty of works3. Workplace and machinery4. Output with correct level of quality5. Less weakness6. Expected delays due to processExercise: sewing machine threading exercise, to calculate SM in SOFT


IDLE TIMEDuring 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 PLANNINGCreative 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 Mins x 80 / 100 = 38400 Mins / day.38400 Mins x 26 days = 998400 Mins /month or 16640 hours/month.


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 Mins x 80 / 100 = 3840 Mins / day3840 Mins x 26 days = 99840 Mins / month or 1664 hours /month.


MAXIMUM CAPACITY:Total hours available under normal conditions in a given period of time.

POTENTIAL CAPACITY:Maximum capacity adjusted for efficiency.

COMMITED CAPACITY: Total hours previously allocated for production during a certain time period.

PRODUCTION CAPACITY AND TYPES

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.


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 capacityAvailable 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?


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 . Monitor daily production delays.

PRODUCTION STANDARDS ARE USED INPRODUCTION PLANNING TO DO THE FOLLOWING :

QUESTION ONE.

Plant capacity is : A 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

QUIZ

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 Mins

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 Machine type Machine qty

1 Join shoulder 2.00 2 Close/set n.Band 4.003 Set sleeve 3.004 Close side 1.505 Close/set cuff 2.506 Close/set w.Ban 3.00

Answer: A- Total Sam/garment:________________________________________ 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 Manpower Req. 1-Turn cuff(2) 0.50 960 12-Turn Col 0.37 1297 13-Turn W Band 0. 40 1200 1Productivity 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 PLANT POTENTIAL CAPACITY IN SAH’S ? IF THE PLANT HAS:

125 MACHINES 6 WORKING HOURS / DAY 5 WORKING DAYS / WEEK EFFICIENCY LEVEL 80%

ANSWER : PLANT CAPACITY / DAY:_125 X 6HR X80%= 600 HRS PLANT CAPACITY / WEEK: 600 HRS X 5 = 3000 HRS

QUESTION THREE.

WHAT WILL BE THE REQUIRED ORDER CAPACITY ? IF THE ORDER DETAILS ARE ORDER QUANTITY : 30,000 GARMENTS SAM / GARMENT = 15 MINS

ANSWER : REQUIRED CAPACITY TOTAL HOURS : 30,000 X 15 SAM/PC / 60 = 7500 HRS DAYS REQUIRED TO COMPLETE ORDER: 7500 HRS

-------------- = 12.5 DAYS 600 HRS/DAY

Question four.Garment breakdown sheet

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 Machine Type Machine Qty1 Join Shld 3.00 160 O/L 2

2 Close/set n.Band 4.50 106 O/L 33 Set sleeve 3.00 160 O/L 24 Close side 1.50 320 O/L 15 Close/set cuff 6.00 80 O/L 46 Close/set w.Band 3.00 160 O/L 2Answer: A- Total Sam / garment : 16 SamB- Total machines required to produce 320 garments/day ? 14

machinesC- How many days required to produce 2880 garments ? 2880 /

320pcs/day= 9 daysD-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

Education

Capacity in apparel industry