Can an Operator Hit 100% Efficiency?

My answer is “yes” your operator can hit 100% efficiency. Provided that the operator has been given with enough work, good workstation layout and a good machine. You know the efficiency calculation formula. For calculating employee efficiency you need a standard time of their task.

The first time many disbelieve me, because they heard that it is impossible. But when I showed them how it is possible, they liked it and get the confidence to hit the target.

You must know how standard minute is being calculated. Let's say the standard time (SAM) is established using a PMTS software. What parameters you add to calculate SAM of an operation? If parameters are set right then you will find few machinists who will hit 100% efficiency.

Here are the eight main parameters those are considered in calculating garment SAM. Before questioning your machinist you must choose correct options from each parameter to establish right SAM of an operation.

1. Machine rpm – Do you provide your operators same machine you used during SAM calculation?
2. Stitch per inch (SPI) – Is SPI used in production same as used in SAM calculation?
3. Stopping Accuracy – what is the right option for your production?
4. The difficulty level in material handling – do you consider the right option for material handling?
5. Seam length – what you do when multiple sizes run on the line? Single SAM for all sizes right?
6. The number of stopping (burst) in a single seam – you may use the standard number provided by a software provider. But you need to think does standard stopping formula works for each operation?
7. Machine allowance as per machine type – you may be right with this.
8. Contingency allowances – you may follow standard allowance percentage.

Where you need to consider all the above parameter to establish the right SAM, there is a chance of making mistake in calculating SAM. Anyway, your SAM will be loose or tight.

Now assume that you have prepared a moderate SAM of an operation. An highly skilled operator can beat your SAM by following ways. 
  1. Taking less stopping (burst) than you considered. In each burst, an operator can save 17 TMU
  2. Utilize less allowance (machine and contingency) than added to the SAM. Approx 22% allowance added to SAM.
  3. Sewing at higher speed (RPM) than you considered in SAM
  4. Using Less SPI when sewing garment
  5. Sewing a seam of shorter length than a length used in SAM calculation
What do you think? 

If you have given SAM of an operation 1 minutes, for a 10 piece bundle standard work time would be 10 minutes. Assuming by applying above tactics the operator make each garment in 0.8 minutes. So bundle completion time will be 8 minutes (for 10 pieces). In this example, operator produced 10 minutes in 8 minutes time. 
Therefore operator;s efficiency will be = (10/8)*100%= 125%

Still don’t want to believe it? 

A British factory reported that their factory run at above 80%. To have a line efficiency of 80%, an individual efficiency of some operators must be greater than 100%.

Share your thought. 



5S,3,Activewear,1,Apparel ERP,4,apparel industry,64,apparel news,38,Apparel Production,38,Apparel Software,35,AQL Chart,1,Attachments,1,Bamboo Fabric,1,Bangladesh,4,Blogs,1,Body Scanner,1,Books,35,Business Guides,14,Buyer,4,Buying House,4,CAD/CAM,2,Calculation & Formula,1,career,39,Change Management,1,China,1,Clothing,3,Clothing Brand,6,Compliance,5,Consumption,4,Costing,21,Cutting,25,Data Analysis,2,Defects,6,Denim,11,Directory,3,Drone,1,Dyeing,3,eCommerce,2,Education,5,End use,1,Event & Fair,19,Fabric,92,Fashion,5,Fashion Business,53,Fashion Design,4,Fashion Show,2,Fiber,6,Finishing,14,Fusing,1,Garment Business,3,Garment Exporters,1,Garment Industry,4,Garmenting,2,Gartex,1,GMT,1,GSM,3,Guest Post,7,Heat sealing,1,Human Resource,8,Incentive system,1,Industrial Engineering,259,Industry 4,1,Infographic,5,Inspiration,1,Institutes,1,Interlining,2,Jeans,4,Knitting,5,KPI,10,Kurti,1,Laser Technology,2,Lean,27,Leggings,2,Line Balancing,4,Line layout,6,Living Wages,1,Machines,47,Manufacturing,57,Merchandising,122,MIS,27,MISC,27,Needle,1,News,5,NIFT,4,Operation bulletin,14,Operator,2,Operator Training,4,Performance rating,1,PLM,7,Printing & Embroidery,14,Problem Solving,2,Production Planning,29,Production System,1,Productivity,2,Project Report,1,QNA,138,Quality,76,Quality Circle,1,Quality manual,2,Quality system,16,Research project,5,Resources,46,Retailing,6,RMG,1,Salary & Wages,7,Sampling,27,Scheduling,6,Seam Sealing,1,Sewing Machine,5,Shirt Making,6,Skiiwear,1,skill Matrix,1,Small-scale business,2,Smart Clothing,1,SMV,1,Sourcing,10,Spec Sheet,10,Sportswear,7,Spreading,2,Stitching,4,Store,2,Stretch fabric,1,Student corner,4,sustainable clothing,10,Sustainable Materials,1,T-shirt,5,Tailor,1,Tailoring Shop,3,Technology,96,Texprocess,1,Textile processing,14,Textile testing,25,Textiles,47,Threads,2,Towel,1,Trims & Accessories,19,videos,11,Washing,3,Waste,1,Wearable Tech,2,Work aids,1,Work Study,48,Work wear,1,WRAP,1,Yoga wear,1,
Online Clothing Study: Can an Operator Hit 100% Efficiency?
Can an Operator Hit 100% Efficiency?
Employee efficiency can be more than 100%.
Online Clothing Study
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 PREMIUM CONTENT IS LOCKED STEP 1: Share. STEP 2: Click the link you shared 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