Can Anybody Hit 100% Efficiency of GSD SAM?

I have intentionally referred it ‘GSD SAM’ because most of the industrial engineers, industry experts and business owners believe that GSD based standard minutes are more accurate than others. You may feel that what a silly question it is. But I met a number of young industrial engineers, who ask me questions in the same way I have titled this article.

My answer is “yes” your operator can hit 100% provided that operator has been fed with enough work, good workstation layout and a good machine. The first time they disbelieve me because they heard that it is impossible. But when I showed them how it is possible, they like it and get the confidence to hit the target.

You must know how standard minute is being calculated. 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 main parameters those are considered in calculating garment SAM. Before questioning your machinist you must choose correct options from each parameter to come out with right SAM.

  1. Machine rpm – do you provide your operators same machine you used in the calculation? 
  2. Stitch per inch (SPI) – Is SPI used in production same as used in SAM? 
  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 get 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 operator can beat your SAM by following ways.
  • Taking less stopping (burst) than you considered. In each burst, an operator can save 17 TMU 
  • Utilize less allowance (machine and contingency) than added to the SAM. Approx 22% allowance added to SAM. 
  • Sewing at higher RPM than you considered in SAM
  • Using Less SPI 
  • Sewing a seam of shorter length than a length used in SAM calculation 
What do you think?

Yet 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%.



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Online Clothing Study: Can Anybody Hit 100% Efficiency of GSD SAM?
Can Anybody Hit 100% Efficiency of GSD SAM?
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