To know the performance of a garment factory and for the comparative study of the sewing line performance, we measure production line efficiency. So, like individual operator efficiency, measuring the efficiency of a production line is important for a factory.
Daily line efficiency data shows line performance for the day. Once you start calculating line efficnecy everyday for your factory and observe the line effiicency trend for a month or a quarter, you will get the average of the Line efficiency.
Production Line Efficiency Calculation - Information required
To calculate the efficiency of a line for a day, you will need the following data (information) from the line supervisor or line recorder.
1. Number of operators – How many operators worked in the line in a day.2. Working hours (Regular and overtime hours) – how many hours each of the operators worked or how many hours the line ran in a day.
3. Production in pieces – How many pieces are produced or total line output at the end of the day
4. Garment SAM – What is the exact standard minute of the style (garment)
Once you have the above data you have to calculate the following using the above information -
a. Total standard minutes produced by the line:
To calculate total produced minutes, multiply production pieces by garment SAM. For example, if one of your production line produced 2000 garments and the item SAM is 3.5 minutes, the total produced minutes is 7000 minutes.
b. Total minutes attended by all operators in the line:
Multiply the number of operators by daily working hours and convert total hours into total minutes (multiplying by 60).
Now, calculate line efficiency using the following formula:
Now, calculate line efficiency using the following formula:
Line efficiency (in percentage) = (Total minutes produced by the line *100) /(Total minutes attended by all operators)
An example - Calculating Production Line Efficiency
Let's calculate the line efficiency of one production line.48 operators worked in a line for 8 hours. They produced 160 garments and the SAM of the garment (style) is 44.25 minutes.
Here,
Total minutes produced = (160 x 44.25) = 7080 minutes
Total minutes attended = (48 operator x 8 hours x 60) = 23040 minutes
Effiicnecy% = (7080 x100)/23040 % = 30.729%
For more examples, refer to the following table. The data calculation formula has been given on the header row of the table.
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| Table: Line Efficiency Report Template |
Here is one Video Guide for calculating overall efficiency.
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 operator efficiency at work?