How to Improve Line Efficiency in a Piece Rate Factory?

SHARE:

Improving line efficiency of the piece rate factory.

How we can increase the efficiency in piece rate basis factory? ... asked by Shaila

Most of us believe that piece rate operators are most efficient in sewing. As machine operators are paid based on the quantity they would produce, they will put maximum effort on their work. Hence one can expect best efficiency of the factory having piece rate operators. But this is not always true. Forget about operator’s maximum effort to produce standard hours (SAH) for a moment. And think on other factors those have direct effect to the line efficiency.

Sewing line

Line efficiency depends on couple of factors than only operators’ efforts. Here are few of those parameters -

  • Skill level of the operators
  • Line balancing 
  • Worker motivation

So to improve the line efficiency (or individual operator efficiency) you can work on the above points

# 1. Skill Training for low performing operators 

Work on training your operators. Use following method to improve operator's skill level.
  1.  Measure operator’s individual efficiency 
  2. Make a list of low performing operators (i.e. operators working at less 50% efficiency). 
  3. Observe your operators while they are working and study their method of performing a jobs and movements.
  4. Check what are the unnecessary motions / movements you found operators are using at the time of sewing. 
  5. Train them correct motions and give them time to practice. 

Once you improve operator’s sewing skills you will see improvement in line efficiency. If you don't know how to train sewing skills to your operators you can hire an expert.

Here I would like to share Paul’s story on skill improvement for low performing experienced operators. This story will explain you that through training you can bring lot of improvement operators earning and line performance.

“Paul Collyer was working as trainer in a garment factory, in UK. He trained a girl how to train operators and build sewing skills. Once she was trained completely, Paul sent her to the sewing floor to find out low performing operators and improve their sewing skills through training.

In that factory most of sewing operators were working for many years. So they were experienced to their job. Operators were paid based on number of pieces they were producing. The factory was running piece rate system.

As instructed by Paul, the young lady went to every operators and studied operator’s performance. She set a method to train low performing operators. When she spoke to experienced operators for the training, they ignored her. Few so called experienced operators used to tell her that they are working for 15 years and they know better than her. They were in the age of her mother. They don’t need to learn anything, at least from the young trainer. The young lady became upset and reported back to Paul. Paul knew this would happen. He told the young lady, “don’t worry, go to operators who have recently joined and improve their skills”. She did the same. 
After several weeks of training, new comers started earning more than the experienced operators. Experienced operators were not able to earn as much as newcomers were earning with their full effort. All the experienced operators got surprised and they acknowledged the benefit of skill training.

All experienced operators who earlier ignored for skill training, met Paul and requested him to send the young trainer to train them better skills so that they can also earn more money.”

I hope now you understand the power of training. There is always scope for improvement. The same way you can improve your line efficiency in your piece rate factory.


#2. Work equalization or balancing of the line.


To produce more pieces, operators must have feeding full time so that they can continuously run their machine. In piece rate factory you may have unbalanced WIP. Work on improving line balancing to improve line efficiency. Read my earlier post on line balancing - How to Balance a Traditional Sewing line?

#3. Performance Incentive


In piece rate production system it is considered that operators are self-motivated in term of their earnings. But sometimes operators do not know their hidden skills and capability of earning more that the current earnings. Implement performance based incentive for piece rate employees also in combination with skill training. You can set differential piece rates for different level of individual operator efficiency. You can also linked performance based incentive based on line efficiency instead of individual operator efficiency.
[post_ads_2]

COMMENTS

You may also like

Name

5S,3,apparel industry,56,apparel news,33,Apparel Production,30,Apparel Software,15,Bamboo Fabric,1,Bangladesh,1,Blogs,1,Books,30,Business Guides,9,Buyer,1,Buying House,4,CAD/CAM,1,Calculation & Formula,1,career,33,Change Management,1,Clothing,1,Clothing Brand,3,Compliance,3,Consumption,4,Costing,7,Cutting,17,Denim,3,Directory,3,Dyeing,1,eCommerce,1,Education,5,Event & Fair,14,Fabric,70,Fashion,5,Fashion Business,36,Fashion Design,3,Fashion Show,1,Fiber,1,Finishing,10,Garment Exporters,1,Garmenting,1,Gartex,1,Guest Post,8,Human Resource,2,Industrial Engineering,208,Infographic,5,Knitting,3,Kurti,1,Lean,27,Line layout,3,Machines,28,Manufacturing,51,Merchandising,101,MIS,23,MISC,20,Operation bulletin,14,Operator,1,Performance rating,1,PLM,2,Printing & Embroidery,11,Problem Solving,1,Production Planning,26,Project Report,1,QNA,120,Quality,61,Quality manual,2,Quality system,14,Resources,42,Retailing,3,Salary & Wages,7,Sampling,22,Scheduling,3,Sourcing,8,Spec Sheet,9,Sportswear,1,Stitching,3,Store,2,Stretch fabric,1,sustainable clothing,7,T-shirt,3,Tailor,1,Tailoring Shop,2,Technology,56,Texprocess,1,Textile processing,11,Textile testing,21,Textiles,41,Threads,1,Towel,1,Trims & Accessories,15,videos,11,Waste,1,Work Study,38,Yoga wear,1,
ltr
item
Online Clothing Study: How to Improve Line Efficiency in a Piece Rate Factory?
How to Improve Line Efficiency in a Piece Rate Factory?
Improving line efficiency of the piece rate factory.
https://2.bp.blogspot.com/-CJnFyXpEfCM/UdeaNfW7odI/AAAAAAAAA90/-hGf-5NfFSQ/s640/readymade+garment+industry+piece+rate.png
https://2.bp.blogspot.com/-CJnFyXpEfCM/UdeaNfW7odI/AAAAAAAAA90/-hGf-5NfFSQ/s72-c/readymade+garment+industry+piece+rate.png
Online Clothing Study
http://www.onlineclothingstudy.com/2013/07/how-to-increase-line-efficiency-in.html
http://www.onlineclothingstudy.com/
http://www.onlineclothingstudy.com/
http://www.onlineclothingstudy.com/2013/07/how-to-increase-line-efficiency-in.html
true
6551124471002606808
UTF-8
Loaded All Posts Not found any posts VIEW ALL Readmore Reply Cancel reply Delete By Home PAGES POSTS View All RECOMMENDED FOR YOU LABEL ARCHIVE SEARCH ALL POSTS Not found any post match with your request Back Home Sunday Monday Tuesday Wednesday Thursday Friday Saturday Sun Mon Tue Wed Thu Fri Sat January February March April May June July August September October November December Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec just now 1 minute ago $$1$$ minutes ago 1 hour ago $$1$$ hours ago Yesterday $$1$$ days ago $$1$$ weeks ago more than 5 weeks ago Followers Follow THIS CONTENT IS PREMIUM Please share to unlock Copy All Code Select All Code All codes were copied to your clipboard Can not copy the codes / texts, please press [CTRL]+[C] (or CMD+C with Mac) to copy