How to Prepare Monthly Efficiency Report of a Sewing Line?

Monthly efficiency figure is one of the basic and very important information to the management of the company. Efficiency figure shows how a line, a floor or a plant is performing compared to other lines and factory standards. Line efficiency level affects the labour cost of the garment. So each line supervisors are given monthly efficiency target to meet the target labour cost. Factory planning and factory capacity are also measured based online efficiency.

In this article, I have explained how the monthly efficiency report of a sewing line is prepared. And how to calculate monthly efficiency report of a sewing floor.

Step 1: Efficiency calculation formula

There is a standard formula to calculate the efficiency of a line. The efficiency calculation method has been explained in another article, How to calculate the efficiency of a production line? Please refer to that article in case you need to know details. Otherwise, just follow the following formula.

Efficiency is a ratio of total minute produced by line and total minutes available to the line. Efficiency is measured in percentage form.

Line efficiency% = (Total Standard minutes produced by a line / Total minutes available to the line) X 100

Step 2: Prepare Monthly efficiency calculation table on spreadsheet (Excel Sheet)

To track monthly production data and manpower details create one table on excl sheet as following that includes information
• No. of operators (include helpers if manual SAM is added to your Operation Bulletin) working in the line
• Total working hours per day
• Total garment produced by the line at the end of the day and
• Standard Minutes (SAM) of the style that is produced by that line

Also add columns for date and styles for reference.

Add three more columns on right side of the table and add formula into the cells of those columns as following
• Total minutes available ( No. of operators X working hours per day X 60)
• Total standard minutes produced (Line output X Garment SAM)
• Efficiency% (Total standard minutes /Total available minutes) * 100

Add 31 rows in the table after table header. Add dates from 1st to 31st on the first (date) column.
 Image-1: Monthly efficiency report (Blank sheet)

Add one more column for monthly totals.

Now your monthly efficiency calculation sheet is ready. See image-1: Blank efficiency report sheet.

Step 3: Data Capturing

At the end of each day fill this sheet date wise with actual information of manpower, working hours, production in pieces and garment SAM.

When month ends, you will have a sheet filled with 31 days data. Exclude or keep blank for holidays and weekly off days. See image – 2.

 Image-2: Monthly efficiency report (Filled sheet)

Step 4: Monthly efficiency of a line

In the row of monthly totals, you have whole month’s data of total minute produced and total minutes available to the line. On the efficiency column you will have monthly line efficiency.

In the above example:

Total minutes available : 751800
Total standard minutes produced : 202953
So, Monthly Efficiency this line is= 27 %

How to calculate floor efficiency?

Now if you have multiple lines in a floor and you to calculate average efficiency of the floor then use following steps.

Step 5: Calculate total minutes available to the floor

• Create same sheet for each line as shown in image-1.
• Fill data line wise. Sum line wise monthly available minutes to calculate total available minutes for a floor.

Step 6: Calculate total standard minutes produced by the floor

Sum up all line’s line wise standard minutes produced to calculate total standard minutes for the floor.

Step 7: Calculate floor efficiency

Finally, use the efficiency calculation formula to calculate sewing floor efficiency.

For example, You have four lines on one floor and line-wise efficiency are as follows.

 Table: Floor efficiency
I hope you understand the above method.