Efficiency Calculation For Garment Factory - A Simplified Method

This post introduces a simplified method for calculating Line Efficiency in a garment manufacturing plant. This straightforward technique enables floor management to quickly determine line performance using only two core variables, providing rapid, actionable insights without complex calculations and data processing.

The variable are  - 

1. Line Output data (Day Total production quantity) 
2. Line Traget Value (Daily)

The straight forward Line Efficiency calculation fomula is as below:

Line Efficiency (%) = (Output Quantity  ÷ Target Quantity) × 100%

Very simple, right? It is assumed that floor management will get the daily production target data from the concerned team on daily basis in advance. 

Floor management must have information of these two variables - (1) Daily production target (at 100% Efficiency) and (2) Line output. 

The line output quantity will be in a fingure tip to the line supervisors. I mean it can be easily colletced from the line output data or the hourly production report. 

The complex part is knowing the daily production target of a production line. The daily production target of the sewing lines is calculated by industrial engineering team using starndard time of the running style and working hours. I will show you the target calculation method in the following section. Before that let's check some examples of Line Efficiency calculation as per above formula.

Example: ABC Fashion Houese has 10 sewing lines and line wise daily target production (at 100% efficiency) is as the following. Actual production quantity is also shown in the table. 

Line-1 Efficiency = (Production quanityt / Target quantity) x 100 

= (340/ 400 ) x100 = 85%

Daily Production Target Calclation:

The production target is derived from availability of resources and garment SAM using the following formula.  

Target Qty = (Number of operators in a Line x Shift time in Minutes)/SAM of the running Style

Example: Let's say 20 operators are assigned to Line-1 and the style SAM is 24 minutes. Plant works 8 hours (480 minutes). 

Therefore, 

Daily Production Target for Line-1 = (20 x 480 ) / 24 = 400 units 

Related Article | How to Calculate Hourly Production Target

Other Formula for Line Efficinecy calculation

The standard efficiency calculation method we used 

= (Output x Garment SAM) ÷ (Manpower x Shift Hour x 60) x 100

When a plant publishes daily production target by lines in the Operation Bulletin (OB) and display on the daily production board, floor perople does not need to know the detailed calculation as shown in these formula and examples.

In a previous articles, I have explained Efficiency Calculation as following:

Both formula will give the same result when you apply the same variables in terms of manpower involved in the line, Style SAM, Shift hours and production quantity. 

Normally, the industrial engineers provide daily target to the lines at reduced line efficiency. You should not consider that targetfor line efficiency calculation. Always use the daily target value that is derived based on 100% of Line Efficiency. 

  

Conclusion:

Factory managers and industrial engineering deparment can leverage Management should Making the Line Efficiency calculation easier and faster for the line supervisors with minimum variables. 

Related Question: 

How to Calculate Hourly and Daily Target When Line Works at 45% & 60% Efficiency?