How to Estimate Garment Production?

Estimating garment production is one of the tasks an engineer and production supervisors do on a daily basis. 

This is the basic requirement for production management and each people who are working in production must know how to estimate daily production in a garment factory. 

Garment production estimation
Shop floor
In this post, I have explained the calculation procedure for estimating daily garment production.

Production is the total number of garments stitched by operators in a line in a day. Production is also termed as daily output. To estimate production, you need the following information.
  1. Standard allowed minutes (SAM) of the garment
  2. How many operators are working in the line?
  3. How many hours line will work in a day?
  4. Average Line efficiency level?
  5. Total break time for lunch and tea break (if any).

The formula for production estimation 

Daily production = (Total man minutes available in a day/SAM) * Average Line efficiency
Total available man-minutes =(Total no. of operators * Working hours in a day * 60)

Let's assume
  • Garment SAM is 20 minutes, 
  • Number of operators is 30 
  • Shift hours in a day = 8 hours
  • Average line efficiency =50
  • Operators get a total of 45 minutes for lunch and tea break.
So, Total available man minutes = 30 *( (8 * 60) – 45) )= 13050 minutes

Daily estimated production = 13050 /20 * 50% = 326 pieces

You can expect this much output from that line if everything goes well.

Daily production quantity from a line is directly proportional to the line efficiency; the number of operators and working hours. And production is reverse proportional to the garment SAM. If the efficiency of a line increases you can expect higher production.

Similarly, if SAM of style reduces at that also you can expect higher output.

Factors that hamper production:

Anyone of the followings can reduce production of the assembly line. So to get estimated output, you have to take on the following areas.
  • Machine breakdown
  • Imbalance line (WIP control)
  • No feeding of cuttings
  • Quality problems
  • Low operator performance 
  • Operator absenteeism
Some of these are non-productive time.

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