Capacity in apparel industry

CAPACITY © SOFT Student Handouts, By, Sunil Talekar, Faculty, SOFT-Pune SunilTalekar Following part are involve while Garment Engineering;  M ethod study  M ethod Improvement  Time Study  Idle Time  Creative Production Planning  Factory Production Capacity  Special M achine Production Capacity 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.  METHOD IMPROVEMENT 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  MAXIMUM CAPACITY: Total hours available under normal conditions in a given period of time.  POTENTIAL CAPACITY: M aximum 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. [...]... 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... ? 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 WH AT WILL BE PLAN T POTEN TIAL CAPACITY IN SAH ’S ? IF TH E PLAN T H AS: 125 M ACH IN ES  6 WORKIN G H OURS / DAY  5 WORKIN G DAYS / WEEK  EF F ICIEN CY LEVEL 80%  AN SWER :  PLAN T CAPACITY / DAY:_125 X 6H R X80%= 600 H RS PL AN T CAPACITY / WEEK:... 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... 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... 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 WHAT ADJUSTM... 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  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... 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... USED IN PRODUCTION PLANNING TO DO THE FOLLOWING :         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... M ODATE THE ORDER IN HAND ?        Require more time from buyer to accommodate the 170 hours Work overtime to cover the 170 hours Increase more machines and operators F ind 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... = 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 EXERCISE TO UNDERSTAND RELATIONSHIP OF CAPACITY TERM S 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 . 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. Time  Creative Production Planning  Factory Production Capacity  Special M achine Production Capacity APPAREL ENGINEERING CONCEPTS  METHOD STUDY The in depth monitoring and analysis of the way. % 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