How to calculate operator efficiency at work?



In apparel manufacturing, skills and expertise of a sewing operator is being presented in “Efficiency” term. An operator with higher efficiency produces more garments than an operator with lower efficiency in the same time frame. When operators work with higher efficiency, manufacturing cost of the factory goes down.


Secondly, factory capacity is estimated according to the operator efficiency or line efficiency. Hence, efficiency is one of the mostly used performance measuring tools. So how do you calculate operator efficiency in factory? To calculate operator efficiency you will be needed standard minutes (SAM) of the garment and operations your operator is making. Use following formula and calculate operator efficiency.

Efficiency calculation formula:
Efficiency (%) = [Total minute produced by an operator/Total minute attended by him *100]

Where,
Total minutes produced = Total pieces made by an operator X SAM of the operation [minutes]
Total minutes attended = Total hours worked on the machine X 60 [minutes]

Example: An operator was doing an operation of SAM 0.50 minutes. In an 8 hours shift day he produces 400 pieces. So according to the efficiency calculating formula, that operator’s overall efficiency
= (400 x 0.50) / (8 X 60)*100%
= 200/480*100%
= 41.67%

On-Standard Operator Efficiency:
Operator efficiency can be expressed in more specific ways, like ‘On-Standard Efficiency’ instead ‘over-all efficiency’. An operator may be attending all hours in a shift but if he has not been given on-standard work to do in all hours, he will not be able to produce minutes as per his capability and skill level. In this case, to know operator’s on-standard efficiency following formula is used.

Operator on-standard efficiency (%) = Total minute produced /Total on-standard minute attended *100%

Where,
Total minutes produced = Total pieces made by an operator X SAM of the operation [minutes]
Total on-standard minute attended = (Total hours worked – Loss time) x 60 [minutes]

Example: An operator was doing an operation of SAM 0.50 minutes. In an 8 hours shift day he produces 400 pieces. Operator was idle ‘waiting for work’ for 30 minutes and his machine broke down for 15 minutes in hours shift. So according to the efficiency calculating formula, that operator’s on-standard efficiency
= (400 x 0.50) / {480 – (30 +15)}*100%
= 200/435*100%
= 45.98%
The above example clarifies that if an operator sits idle during shift hours his overall efficiency will go down.



Related Topics:
How to calculate SAM for a garment?
Garment CM cost estimation using SAM or SMV
The Concept of Operator's Performance Rating
How to calculate efficiency of a batch or line?
How to calculate operator efficiency at work?