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. 

Post a Comment

Previous Post Next Post

Contact Form