How to Calculate Sewing Operator Efficiency in Garment Industry

Shafiun Nahar Elma
Industrial & Production Engineer
National Institute of Textile Engineering & Research (NITER), Bangladesh.
Email: [email protected]

Introduction:
In the rapidly growing garment industry, productivity needs a boost to continue leading and succeeding in the market. Ever wondered how sewing operator efficiency is measured? This writing will unravel the secrets of calculating their efficiency, show you reasons why it matters, and share practical tips on how to elevate this essential part of garment production.

Importance of Calculating Sewing Operator Efficiency:
Sewing operator efficiency is all about how well workers wield those sewing machines in a garment factory. It’s like a dance of time and productivity.

When efficiency upgrades, operators whip up garments faster than expected. But when it dips, it’s a red flag that something’s inappropriate that needs fixing. Are they struggling with their rhythm, or is there a bottomless issue?

Why Calculate Sewing Operator Efficiency?
Calculate sewing operator efficiency is very important for several reasons:

1. Top management and bottom management can rightly understand the performance of an individual and his team.
2. Efficiency tends to allow costs to be reduced and for resources to be judiciously applied.
3. Efficient operators make better garments with fewer defects.
4. Identified inefficiencies pinpoint where further training or support is needed.
5. It’s the means of stacking up against industry standards or competitors.

How to Calculate Sewing Operator Efficiency?
In this respect, efficient calculation of sewing operator efficiency can be determined through the following steps:

Step 1: Collection of data

Before calculate sewing operator efficiency data needs to first be collected regarding sewing operator efficiency which includes total working time, such as the total number of hours that an operator works in a day or a week, and Total Pieces Produced is the pieces he produces in that particular time frame.

Standard Allowed Minutes (SAM): Time booked to perform a specific task or garment constructed on the industry standards.

Output Quantity: Total number of garments produced by an operator within that time.

Step 2: Calculate the total production time

Total Production Time = Output Quantity × SAM

Step 3: Calculate sewing operator efficiency

Having received the total production time, you can calculate sewing operator efficiency by using the formula below:

Efficiency (%) = (Total Production Time / Total Working Time) × 100

Example: Suppose an operator is producing 100 garments, each taking a minute.

In an 8-hour duty, that is 480 minutes of potential.

1. Total Production Time -Just 100 minutes.
2. Efficiency? (100 min / 480 min) × 100 = 20.83%.

Thus, the operator’s efficiency drifts around 20.83%. Quite some parentage gaining, isn’t it?

Step 4: Analyze results

After calculating sewing operator efficiency, it is required to analyze the results. Find patterns over time, compare efficiencies across operators or teams, and identify what causes low efficiencies.

Sewing-Related Calculations:

1. SMV Calculation

Formula:

SMV = (Observed Time × rating / 100) + Allowances

2. Production Efficiency of Sewing Line

Formula:

Calculate Swing Operator Efficiency in Line (%) = Total Produced Garments × SMV / Total Available Minutes for All Operators × 100

3. Calculation of Machine Downtime

Calculate sewing operator efficiency depends on machine ‘downtime’. Downtime as a percentage gives us an idea regarding the lost time of production.

Formula:

Downtime (%) = (Downtime minutes / Total available minutes) × 100

4. Target Output Per Operator

This calculation gives the expected quantity of production that an operator is supposed to have based on the SAM or SMV of the task.

Formula

Target output = Total working minutes / SMV

Factors Affecting Calculate Sewing Operator Efficiency:

a) Skill Level: A seasoned operator dances through the fabric, making fewer mistakes. Practice is the magic wand that speeds up the procedure.

b) Machine Condition: A well-tuned machine hums like a happy tune. Neglect it, and it sputters. Regular TLC keeps the gears turning smoothly.

c) Training and Support: Imagine the confidence a little training can instill! Ongoing support transforms operators into skilled artisans, elevating their efficiency to new heights.

d) Management Practices: Optimization of the operating processes of an organization can facilitate the use of proper communication, goal setting, and acknowledgment of performance to assist operators in improving their efficiency.

Methods to Enhance Output among Sewing Operators

1. Implement Training Programs: Courses should be taken periodically by the operators to increase their competence levels and also to enable them to implement proper current industry practices in garment production.

2. Optimize Workflow: Study definable activity flow patterns to determine areas of weakness in the production system. Optimization of these activities translates into vast enhancements in the efficiency of operations.

3. Invest in Technology: The high cost of sewing machines that are fitted with advanced technology to speed up production could also lead to increased productivity due to reduced time of machine breakdown and better quality of the products.

4. Foster a Positive Work Environment: Largely, the productivity of the employees depends on the perception they have towards the general working environment and their physical working conditions.

5. Set Clear Goals and KPIs: The performance improvement should include setting measurable performance targets and or objectives coupled with standard KPIs that sewing operators can work towards. The above targets must be revised from time to time and appropriate feedback on these activities should be given.

Conclusion:
The cost and calculate sewing operator efficiency are one of the most important issues to control productivity in the garment sector. Recognizing how to compute this factor is beneficial for companies since it can point towards issues hindering efficiency and allow for strategies that can help with the condition to be acted upon.

In this article, we reveal some effective methods garment manufacturers can apply to enhance sewing operator efficiency, including skill development, effective workflow, modern technology, good human relations, and clear objectives. It not only results in ever higher levels of output but also ensures better quality and happier workers both important factors in a cutthroat garment manufacturing industry.

Lastly, concerning one of the work’s major findings, it means that calculated sewing operators’ efficiency constantly gives useful information about the workforce performance as well as reveals possibilities of development that are useful for both employees and the organization as a whole.

References:

1. https://www.onlineclothingstudy.com/2011/02/how-to-calculate-sam-of-garment.html
2. https://leanstitch.com/industrial-engineering-calculations-garment-production-factory/
3. https://www.onlineclothingstudy.com/2011/09/how-to-calculate-operator-efficiency.html
4. https://www.textilecalculations.com/how-to-calculate-operator-efficiency-in-textile-garments-industry/
5. https://www.academia.edu/33142141/Ways_to_Increase_Sewing_Operator_Efficiency

Founder & Editor of Textile Learner. He is a Textile Consultant, Blogger & Entrepreneur. He is working as a textile consultant in several local and international companies. He is also a contributor of Wikipedia.

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