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Showing posts from June, 2019

What is Standing Time in the Garment Manufacturing Process

In the garment manufacturing, Standard Time (SAM/SMV) is a common term. But when someone asked me about the 'Standing Time', I thought he might be using the wrong word for standard time. This term 'Standing Time' was new to me.

I asked him whether he is talking about Standard Time of a garment. If not where he found this term.

He confirmed that it is standing time. This term is used in Fast React planning system. But he doesn't know the meaning of  'Standing Time'.

I checked with a Fastreact system user and got the answer.

As per the Fastreact user, standing time means waiting time between two processes. Like, waiting time in between embroidery and stitching process. In production scheduling and event planning, waiting time in between two processes are considered. 

Though the 'Standing Time' is a term used by a software system, it is good to know the meaning and use of this term.

Garment Production and Piece-rate Pay

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In a piece-rate pay system, workers get paid based on the number of garments they produce. Pay amount = (Number of garments produced x piece rate).

You know, as garment components and unfinished garments move through the garment processes (like cutting to printing, embroidery, stitching, checking, initial finishing, repairing, pressing, final checking, packing etc.) gradually the number of garments reduce. The packing quantity will be lesser compared to the cut quantity. Inside the production line, some garments got damaged or somehow factory loss some garment in the stitching section. Consider factory is capturing correct production data.

In the initial finishing and final finishing stage factory got a different garment quantity which is less than the stitched garments. Further in shipping, we see more reduction in shipped quantity than the packed garments.

Now the question is - to calculate worker’s pay amount for the piece-rate employees, from which stage of the garmenting pro…

Real-time Production Tracking System - All that You will Get from Scanning Bundle Tags

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A real-time production tracking system has the capability to capture bundle start time (with timestamp) and bundle end time at each operation for each bundle and units. ( I am talking about the system for readymade garment manufacturing). You can capture workers standard work time, idle time, and non-productive time against various non-productive categories. All these trackings are done at the operator's terminal by operators.

The objective of a real-time system is getting accurate information at the right time. So that line supervisors and the work-study team can act for managing the line and sewing floor. In a bigger object, managing orders and reducing labour cost. You can’t imagine the depth of data you can have through bundle scanning.

All that you will get from an RFID based real-time system.

Cycle time of each operation as system captures start and stop time for each bundle (or each individual unit)

SAH produced by individual workers and by the line

Standard hours w…

What is SMV (Standard Minute Value)

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The full form of SMV is Standard Minute Value. The work study team and industrial engineers in the garment industry, use 'SMV' term to define the standard time of an individual garment operation as well as for the whole garment SMV. The SAM is another term used for standard time.
What is SMV Considering the SMV as the standard time required for making each garment, factory plans manpower and machine requirement for the garment orders.

The daily production target of a line is calculated from the SMV. 
Individual employee performance, as well as the production line's performance, is measured based on SMV produced by the employee and by the line.

For example, say SMV of a shirt is 22 minutes (including stitching and non-stitching operations), that means the established standard time for the shirt is 22 minute (given time).

The Garment SMV is used for labour costing for garment production. SMV is used for performance benchmarking as well.

You see the importance of the S…

First Step for Improving Factory Efficiency

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A factory owner asked - I know our factory efficiency is low. To improve my factory efficiency what should I do first?

In case you are not measuring line efficiency and factory efficiency, the first step would be measuring the existing factory efficiency. Remember "what gets measured, gets improved". So, you can not avoid this step.

If you are already measuring line efficiency and factory efficiency, your first step would be capturing off-standard time (non-productive time) where your standard time is not being utilized. This data will show you where the improvement potential is lying.
Measuring factory efficiency To measure and calculate the factory efficiency you first need to calculate line wise daily efficiency. Check the post on calculating daily line efficiency. Note, you can calculate line efficiency based on the line output quantity. Another way of calculating line efficiency is calculating individual operators produced SAM and summing up to get total SAM produced b…

Major Factors Affecting Factory Efficiency

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One of the OCS readers asked this question - What are the major factors that affect factory efficiency directly? 
The right answer to this question depends on the current factory practices. Depends on the production systems, workflow and effectiveness of the managerial team. The direct reason may vary from one company to another.

In general, the following are the key factors that may cause maintaining and improving factory efficiency in garment manufacturing.

1. An imbalance production line  If you are having assembly lines and workload are not balanced in a line between workers, some workers will not get enough work for the day. And a few workers will have a pile of works. This situation causes the utilization of standard hours which in turn affect the line efficiency.
2. Unmeasured lost time and no action on lost time reduction  The time when workers are not doing standard work and waste their time being idle is called as lost time. Many times in a day, operator wait for work (feed…

How to Justify the Piece Rate in the Garment Industry?

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You know, many garment companies calculate workers payment based on the operation piece rate. This payment system is widely used across the globe. Secondly, this is a very simple way of calculating workers payment, once the piece-rate is agreed. Garment companies decide the piece-rate per garment per operation after the style is loaded to a production line. My question is, how do you justify the garment piece-rate that is agreed between the worker and the company management?



It is true that workers are motivated by the piece-rate payment system. Operators earning is directly related to their production qty. The factory management also gets confidence that workers will work at their maximum speed to earn more money. Factory owners feel satisfied that their workers are motivated.

How the piece-rate is derived for a stitching operation? In most cases, piece rate is finalized after a negotiation with operators, contractor and calculate daily earning capability of their operators (Num…

PLM Buyer's Guide 2019 by WhichPLM

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I am sharing this PLM buyer's guide 2019 (Free PDF download) if you missed it downloading from WhichPLM. From this guide, you will learn about different technology solutions available for the sewn product industry. A must-read guide for students. 
Related: What is PLM software? This buyer's guide includes insights into 18 different digital solutions categories. From 3D and digital printing to storyboards and trend analysis, we believe these solutions are going to shape the future of fashion technology. This analysis is essential reading for anyone currently looking to design a complete digital ecosystem.
Download your copy of the PLM Buyer’s Guide 2019 here.
You can share your learning here after reading the PLM Guide.
(Disclaimer: I am not promoting any solution provider. The uploaded guide is hosted by whichplm.com. I am just sharing the download link for your learning purpose)  

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