The garment manufacturing and exporting industry is facing
heavy challenges due to various factors including global competition,
production costs increase, less productivity/efficiency, labor attrition, etc.
the basic fact that our country has immense strength in human resources itself
is the motivating aspect to feel for such an analysis. For overcoming those
challenges our need industrial engineering knowledge.
Industrial engineers (IEs) are responsible for designing
integrated systems of people, machines, material, energy, and information.
Industrial engineers figure out how to do things better. They engineer
processes and systems that improve quality and productivity. They work to
eliminate waste of time, money, materials, energy, and other resources. This is
why more and more companies are hiring industrial engineers and then promoting
them into management positions. .
We can see at a glance of IE,
Industrial Engineering (IE) = Production ↑ Cost ↓ Proper use of all elements ↑ Efficiency ↑ Profit ↑
I’m giving some formula for Industrial engineering students or professionals.
If those help them then I will be thankful.
6. Standard Pitch Time (S.P.T) = Basic Pitch Time (B.P.T) + Allowances (%)
7. GSD
GSD = (Man power * Work hour) / Target
8. SMV
SMV = Basic time + (Basic time * Allowance)
9. Basic time
Basic time = Observed time * Rating
10. Observed time
Observed time = Total Cycle time / No of cycle
11. Rating
Rating = (Observed Rating * Standard rating) / Standard rating
12. Earn minute
Earn minute = No of Pc’s (Production) * Garments SMV
13. Available minute
Available minute = Work hour * Manpower
14. Organization Efficiency
Organization Efficiency = (Basic pis time / Bottle neck time) * 100
15. Basic pis time (BPT)
Basic pis time = Total GMT SMV / Total Manpower
16. UCL
UCL = Basic pis time / Organization Efficiency
17. LCL
LCL = 2 * Basic pis time – UCL
18. Capacity
Capacity = 60 / Capacity time in minute
19. Cycle Time
Cycle Time = 60 / Team target
20. Capacity Achievable
Capacity Achievable = Capacity * Balance
21. Daily output
Daily output = Work hour / SMV
22. Factory capacity
Factory capacity = (Work hour / SMV) * Total worker * Working day * Efficiency
23. CPM
CPM = (Total over head cost of the month / No of SMV earners Work minutes)
*Efficiency
24. Required no of operator
Required no of operator = Target daily output / Daily output per operator
25. Efficiency
Efficiency = (Earn minute * Available minute) * 100
- See more at:
http://textilecalculation.blogspot.com/2014/11/some-important-formula-for-industrial.html#sthash.ULNjBipl.dpuf
Introduction:
Calculation Method of Standard
Minute (SAM or SMV) in Apparel Industry:
An industrial engineer should follow the below formula for calculating SAM
or SMV.
SAM = (Basic minute + Bundle allowances + Machine and Personal
allowances)…… (1)
Normally bundle allowances should be added 10% with basic time and Machine
and Personal allowances added 20% with basic time.
The main thing here, the determination of “Basic minute”. It can be done by
two ways. Both ways have discussed in this article.
Method-01:
In this case, SAM or SMV Calculation can be done by using synthetic data.
At first an industrial engineer has to fix anoperation, for which he wants to estimate SAM or SMV.
http://garmentsstudybd.blogspot.com
Here, he should
stand near the m/c operator and follow the every working procedure for the
selected operation. He should note all the activities done by the operator
(these activities are called synthetic data collection). When all the
activities of operator will complete, then industrial engineer should follow
the same activities of operator again to check the noted activities that the
note is ok or not.
Now,
industrial engineer should list down all the activities of operator in
sequentially and refer the synthetic data for TMU (time measuring unit) values.
Suppose, industrial engineer got TMU value for that operation is 450. Now he
should convert total TMU into minutes, where (1TMU= 0.0006 minute). So for
450TMU= (450 × 0.0006) = 0.27minute. This minute is termed as Basic time.
So, now from equation-01, we get,
SAM or SMV = (Basic minute + Bundle
allowances + Machine and Personal allowances)
= 0.27 + (0.27 × 10%) + (0.27 × 20%)
= 0.27 + 0.027 + 0.054
= 0.351minute
So, SAM or SMV value for that operation is 0.351
minute.
Method-02:
In this case, SAM or SMV Calculation can be done by using time study.
Here,
industrial engineer should take a stop watch and stands near the m/c operator.
Capture cycle time for that operation (that he chosen early). Cycle time means
“total time needed to complete full operation”. He should be done this process
consecutively at least for 5 cycle times. Then he should calculate mean cycle
time by adding 5 cycle times and divided those by 5. Finally industrial
engineer gets the cycle time here. (Let, cycle time here 0.50) Now, he should
convert cycle times into basic time by multiplying with “performance rating”.
So, Basic time = Cycle time × Performance
rating ………………. (2)
Performance
rating:
Performance rating is related with m/c operator. In
which speed, operator completed his duty. It’s determined by industrial
engineer. Let, the operator performance rating was- 70%.
So, from equation (2), we get,
Basic time = 0.5 × 70% [Cycle time= 0.5] = 0.35
So, basic time= 0.35
By using equation- (1), now we get,
SAM or SMV = (Basic minute + Bundle allowances + Machine and Personal
allowances)
= 0.35 + (0.35 × 10%) + (0.35 × 20%)
= 0.35+ 0.035 + 0.07
= 0.46 minute
So, SAM or SMV for that operation stands at 0.46
minute.
Calculate
the CM (Cost of Making) of a Garment
B.Sc. in TEXTILE
MIS
SUAD GARMENTS INDUSTRIES LTD, Narayongonj
Email: marzuk.suad@gmail.com
Introduction:
Normally at present (after starting the new salary scale) in Bangladesh we calculate
the CM of any item consider the overhead sewing machine cost 1200 tk to 1400
tk/day that means $15.38 to $17.95/per day.
Above is for a non-compliance factory. For a compliance factory the per day
machine cost will be 1800 tk to 2100 tk ( $23.08 to $26.92).
Example :
If an items produce 1600 pcs per day using 25 machines then
what would be the CM cost ???
Solution:
CM cost = Overhead machine cost X require machine / produce quantity X 12
= (1800 X 25 / 1600 )X 12
= 337.5 Taka
= $ 337.5/78
= $ 4.32 /dozen
Calculate the CM of a Garment
Calculate the CM after discussion with your production
department. It’s vary depends on require machine qty & output qty.
To find out the CM of a item you must need the following 06
(six) information at first, as listed below
- Monthly
total expenditure of your factory with factory rent, commercial cost,
electricity bill, water bill, transportation, repairing, worker &
stuff wages etc. (8hrs/day) in bangla taka. Suppose-50,00,000/tk
- Qty
of running Machine of your factory of the following month (which total
expenditure we have consider here).Suppose- 100 machine.
- Number
of machine to complete the layout for the following Items (which CM we are
calculating). Suppose - 25 machines .
- Production
target/capacity of the following items, per hour from the existing layout,
excluding alter & reject. Suppose 200 pcs per hour.
- Total
working day of the followings month,(though the house rent,commercial
expenses, machine overhauling & some other cost remain same)Suppose- 26 days.
- If
you want to calculate the CM in US$ (dollar) then pls input present dollar
conversation rate BDTk. Suppose $1 = 78 tk.
COST OF MAKING (CM)
=
(SAM of the garment * Minute cost of the labor) / Line
efficiency (%)
OR
= Overhead machine cost X require machine / produce quantity
= [{Monthly total expenditure of the following factory / (26 X Qty of running
Machine of your factory of the following month)}] X (Number of machine to
complete the layout) / produce quantity per day.
= [{50,00,000 / (26 X 100 )} X 25] / {(200) X 8}] X 12
= [{192307.7 / (100) X (25) } / 1600] X 12
= (48,076.9 / 1600) X 12
= 30.048 X 12
= 360.58 Taka
= $ 360.58/ 78
= $ 4.62/dozen
This is the making cost (12 pcs) garments.
- See more at:
http://textilecalculation.blogspot.com/2014/11/calculate-cm-cost-of-making-of-garment.html#sthash.xJM627DO.dpuf
