Capacity in apparel industry

CAPACITY
© SOFT Student Handouts,
By, Sunil Talekar, Faculty, SOFT-Pune
SunilTalekar
Following part are involve while Garment
Engineering;

M ethod study

M ethod Improvement

Time Study

Idle Time

Creative Production Planning

Factory Production Capacity

Special M achine Production Capacity
APPAREL ENGINEERING CONCEPTS

METHOD STUDY
The in depth monitoring and analysis of the way an operator
performs its task is called method study.
Three to four method study will guide you to select the right method
to perform any operation and the we can proceed for next operation as
well to find out the causes of delay in the process of stitching.

METHOD IMPROVEMENT
Once the method study is done, one looks for better ways to save

time and less effort by the operator. This could be done by improving
work motions / provide work aids like gauges , folders , attachments ,
trolleys , movers, tracks or machine automation.
APPAREL ENGINEERING CONCEPTS

TIM E STUDY
The recording of time of every motion conducted by the operator is
termed as time study. Once the time is recorded, allowances for fatigue,
machine delays , personal breaks and various times are integrated into the
pure time to derive real time. This time is termed as SAM ( Standard
Allowed M inutes) of SM V ( Standard M inute Value ).
Time study will guide us to calculate the standard minutes for any
specific operation and it is the average for one cycle of an operation that
we would measure over a typical day if we had;
1. A skilled operators
2. Plenty of works
3. Workplace and machinery
4. Output with correct level of quality
5. Less weakness
6. Expected delays due to process
Exercise: sewing machine threading exercise, to calculate SM in SOFT
APPAREL ENGINEERING CONCEPTS

IDLE TIM E
During the course of production, it is observed that
operators are idle and wait for production buildup to
make them go into motion, this idle time is loss of time
and production.

CREATIVE PRODUCTION PLANNING

Creative production planning is use of various
techniques to assure that idle time is less or eliminated .
more production in less time is key to success for any
manufacturing plant.
APPAREL ENGIEERING CONCEPTS

FACTORY PRODUCTION CAPACITY
Factory production capacity is derived from the resources
available at the manufacturing plant . It is calculated simply by the
amount of machines available and hours per day determined to work
to be realistic ,one has to determine the efficiency level of the
operators and incorporate the percentage to derive actual capacity.
Example : if a factory has 100 machines and working hours are 8
hours per day and 26 days per month . the efficiency level of
operators is observed to be at 80% . the production capacity available
time per month would be calculated as below :
Available monthly production time capacity :
100 machines x 480 M ins x 80 / 100 = 38400 M ins / day.
38400 M ins x 26 days = 998400 M ins /month or 16640
hours/month.
APPAREL ENGINEERING CONCEPTS

SPECIAL MACHINE PRODUCTION CAPACITY
Once planning production , it has to be known that if any special
operation is required within the garment which require special
machine or machines . if so , the output capacity for those garments
have to based upon special machine production . the management
can then decide if those machines be worked overtime or if required
to meet shipment date , additional machines be purchased .
To calculate special machine capacity per month , the available

machines are 10 , work hours /day are 8 hours , efficiency level is
80% and working days per month is 26 days.
Special production capacity in time / month =
10 machines x 480 M ins x 80 / 100 = 3840 M ins / day
3840 M ins x 26 days = 99840 M ins / month or 1664 hours
/month.
APPAREL ENGINEERING CONCEPTS

MAXIMUM CAPACITY:
Total hours available under normal conditions in a
given period of time.

POTENTIAL CAPACITY:
M aximum capacity adjusted for efficiency.

COMMITED CAPACITY:
Total hours previously allocated for production
during a certain time period.
PRODUCTION CAPACITY AND TYPES

AVAILABLE CAPACITY :
Difference between potential capacity and committed
capacity for a certain time period .

REQUIRED CAPACITY :
Sam or SAH necessary to produce a specified volume
in a certain time period .

EXCESS CAPACITY :
Difference between potential capacity and required

capacity .
PRODUCTION CAPACITY
Lets say ABC garments company has 20 operators who
work 8 hours a day. The plant has 90% efficiency level.
Working shift is 8 hours a day in which 1 hour is mainly for
lunch and tea time break.
So their potential capacity for next 10 days will be,
20 machines x 7 hours /day = 140 hours/day x 90% efficiency = 126 potential
production hours /day.
Potential capacity for 10 days = 10 days x 126 hours = 1260 hours
potential capacity.
EXERCISE TO UNDERSTAND
RELATIONSHIP OF CAPACITY TERMS.
EXERCISE TO UNDERSTAND
RELATIONSHIP OF CAPACITY TERMS.
A Sale brings in order for 10000 units of style “ax” that needs to be delivered in
10 days . the plant already has a committed capacity of 600 hours for the 10
days period. It was established that style “ a” has a production time of 5
SAM .
So their required capacity for 10000 units will be;
5 SAM /unit x 10000 units = 50,000 SAM or 833 SAH to
complete the order. Capacity required = 833 hours.
What is available capacity in the plant currently ?
Ans. Available capacity = potential capacity – committed
capacity
Available capacity = 1260 hours – 600 hours = 660
hours available
Lets say ABC garments company has 10 operators who
work 8 hours a day. The plant has 90% efficiency level. A
customer brings in order for 6000 units of style “a” that

needs to be delivered in 10 days . the plant already has a
committed capacity of 300 hours for the 10 days period.
Working shift is 8 hours a day in which 1 hour is mainly
for lunch and tea time break.
It was established that style “ a” has a production time
of 5 SAM . The order of 6000 units require 30,000 SAM
( 500 hours ). What factors should be considered in
deciding whether to accept the order or refuse?
EXERCISE TO UNDERSTAND
RELATIONSHIP OF CAPACITY TERMS.
What is the potential capacity of united garments company for
the 10 working days ?
Ans. 10 machines x 7 hours /day = 70 hours/day x 90% efficiency = 63 potential
production hours /day.
Potential capacity for 10 days = 10 days x 63 hours = 630 hours potential
capacity.
What is required capacity for the 6000 unit order ?
Ans. 5 SAM /unit x 6000 units = 30,000 SAM or 500 SAH to complete the order.
Capacity required = 500 hours.
What is available capacity in the plant currently ?
Ans. Available capacity = potential capacity – committed capacity
Available capacity = 630 hours – 300 hours = 330 hours available
Is available capacity adequate to accept the order ?
Ans. 330 hours of available capacity – 500 hours of required capacity = -170 hours
Capacity is not sufficient to accept order .

Require more time from buyer to accommodate the 170
hours .

Work overtime to cover the 170 hours.


Increase more machines and operators .

Find way to increase efficiency level to 100 % .

Use creative production technique to increase
productivity .

Try to eliminate idle time within production to decrease
throughput time .

Assess the performance of individual operators.
WHAT ADJUSTMENT HAS TO BE MADE TO
ACCOMMODATE THE ORDER IN HAND ?

Estimate the rate or time for completion of each
operation.

Determine the required capacity for an order or style.

Determine the production start dates and completion
dates for orders.

Plan the daily volume that should have been completed.

Determine the backup inventory needed to support the
work flow.

Determine how many operaqtors and machines should be
performing on each operation.


Schedule specialized equipment .

M onitor daily production delays.
PRODUCTION STANDARDS ARE USED IN
PRODUCTION PLANNING TO DO THE FOLLOWING :
QUESTION ON E.
Plant capacity is :

A projection of the total hours available for production in a given time period.

Number of garments a plant can produce in a certain time period

Number of machines available to meet the capacity of orders
Committed capacity is :

The orders which P.O. Still not received

Orders waiting for confirmation

Total hours previously allocated for production in certain time
Available capacity is :

The volume which can be still produced in a plant

The styles which orders can be taken and ship on time

The difference between plant capacity and committed capacity for a certain time period
If a garment has Sam = 6 min . the plant capacity is 4800 min/day . efficiency of plant at 100% .
how many days will it take to produce 12000 garments ? how many machines does the plant own ?


10 days . 10 machines

2.5 days . 20 machines

5 days . 40 machines

15 days . 10 machines
QUIZ
QUESTION TWO .
What will be plant potential capacity ? If the plant has:

125 machines

6 working hours / day

5 working days / week

Efficiency level 80%
Answer : Plant capacity / day:_____________________
Plant capacity / week:____________________
QUESTION THREE.
What will be the required order capacity ? If the order details are :

Order quantity : 30,000 garments

Sam / garment = 15 M ins
Answer : Required capacity total hours :______________________
Days required to complete order:___________________
QUIZ

Product description :
Fleece top L/S with neck band / cuff & w. Band all sewn on over lock machines.
Fill in blanks. 8 hours work time /day. 26days/month. 100% efficiency.
Op no Operation Sam Prod/day M achine type M achine qty
1 Join shoulder 2.00
2 Close/set n.Band 4.00
3 Set sleeve 3.00
4 Close side 1.50
5 Close/set cuff 2.50
6 Close/set w.Ban 3.00
Answer:

A- Total Sam/garment:________________________________________

B-Total machines required to produce 320 garments/day? _______________

C-How many days required to produce 2880 garments? _________________

D- how many machines required to produce 24,000 in 20 days? ______________
QUESTION FOUR GARMENT BREAKDOWN SHEET
Equipment requirement : O/L = 19

Production output target = 1000 units per day.
Indirect labor:
Operation SAM Prod/day M anpower Req.

1-Turn cuff(2) 0.50 960 1
2-Turn Col 0.37 1297 1
3-Turn W Band 0. 40 1200 1
Productivity increase: 8.567 – 7.290 = 1.277 / 8.567 = 15 %

Separating indirect labor resulted into :

15% productivity increase. 1000+150 = 1150 output

19 machines-16 machines = 3 less machines

Indirect labor cost ½ the operator cost saved.

3 machines less inline . less space.

3 less machine . machine cost saved.
Quiz . ( Answer Sheet )
Question one.
Plant capacity is :

Projection of the total hours available for production in a given time period.

Number of garments a plant can produce in a certain time period

Number of machines available to meet the capacity of orders
Committed capacity is :

The orders which P.O. Still not received

Orders waiting for confirmation

Total hours previously allocated for production in certain time
Available capacity is :

The volume which can be still produced in a plant


The styles which orders can be taken and ship on time

The difference between plant capacity and committed capacity for a certain time period
If a garment has Sam = 6 min . the plant capacity is 4800 min/day . efficiency of plant at
100% . how many days will it take to produce 12000 garments ? how many machines does the
plant own ?

10 days . 10 machines

2.5 days . 20 machines

5 days . 40 machines

15 days . 10 machines

QUESTION TWO .
WHAT WILL BE PLAN T POTEN TIAL CAPACITY IN SAH’S ? IF THE PLANT HAS:

125 M ACHINES

6 WORKIN G HOURS / DAY

5 WORKING DAYS / WEEK

EFFICIEN CY LEVEL 80%
ANSWER : PLAN T CAPACITY / DAY:_125 X 6HR X80%= 600 HRS
PLAN T CAPACITY / WEEK: 600 HRS X 5 = 3000 HRS

QUESTION THREE.

WHAT WILL BE THE REQUIRED ORDER CAPACITY ? IF THE ORDER DETAILS ARE

ORDER QUANTITY : 30,000 GARM ENTS

SAM / GARM EN T = 15 M INS
ANSWER : REQUIRED CAPACITY TOTAL H OURS : 30,000 X 15 SAM /PC / 60 = 7500 HRS
DAYS REQUIRED TO COM PLETE ORDER: 7500 HRS
= 12.5 DAYS
600 HRS/DAY
Question four.
Garment breakdown sheet
Product description :
Fleece top L/S with neck band / cuff & w. Band all sewn on over lock machines.
Fill in blanks. 8 hours work time /day. 26days/month. 100% efficiency.
Op No Operation Sam Prod/day M achine Type M achine Qty
1 Join Shld 3.00 160 O/L 2
2 Close/set n.Band 4.50 106 O/L 3
3 Set sleeve 3.00 160 O/L 2
4 Close side 1.50 320 O/L 1
5 Close/set cuff 6.00 80 O/L 4
6 Close/set w.Band 3.00 160 O/L 2
Answer:
A- Total Sam / garment : 16 Sam
B- Total machines required to produce 320 garments/day ? 14 machines
C- How many days required to produce 2880 garments ? 2880 / 320pcs/day=
9 days
D-How many machines required to produce 24,000 in 20 days ? ?
24,000 / 20 days = 1200 units Req./day. 1200 units x 16 Sam
= 19200 Sam/ 480mins= 40 machine
THANK YOU