CAPACITY
CALCULATION
APPAREL ENGINEERING CONCEPTS
Following part are involve while Garment Engineering;
Method study
Method Improvement
Time Study
Idle Time
Creative Production Planning
Factory Production Capacity
Special Machine 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
TIME 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
Minutes) of SMV ( Standard Minute 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
APPAREL ENGIEERING
CONCEPTS
IDLE TIME
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 ENGINEERING
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 Mins x 80 / 100 = 38400 Mins / day.
38400 Mins x 26 days = 998400 Mins /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 Mins x 80 / 100 = 3840 Mins / day
3840 Mins x 26 days = 99840 Mins / month or 1664 hours /month.
PRODUCTION CAPACITY AND
TYPES
MAXIMUM CAPACITY:
Total hours available under normal conditions in a
given period of time.
POTENTIAL CAPACITY:
Maximum capacity adjusted for efficiency.
COMMITED CAPACITY:
Total hours previously allocated for production during a
certain time period.
PRODUCTION CAPACITY
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 .
EXERCISE TO UNDERSTAND
RELATIONSHIP OF CAPACITY TERMS.
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.
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
EXERCISE TO UNDERSTAND
RELATIONSHIP OF CAPACITY TERMS.
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?
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 .
WHAT ADJUSTMENT HAS TO BE MADE
TO ACCOMMODATE THE ORDER IN
HAND ?
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.
PRODUCTION STANDARDS ARE USED IN
PRODUCTION PLANNING TO DO THE FOLLOWING :
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 operators and machines should be
performing on each operation.
Schedule specialized equipment .
Monitor daily production delays.
QUIZ
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
QUESTION ONE.
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 Mins
Answer : Required capacity total hours :______________________
Days required to complete order:___________________
Quiz . ( Answer Sheet )
Question one.
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 PLANT POTENTIAL CAPACITY IN SAH’S ? IF THE PLANT HAS:
125 MACHINES
6 WORKING HOURS / DAY
5 WORKING DAYS / WEEK
EFFICIENCY LEVEL 80%
ANSWER : PLANT CAPACITY / DAY:_125 X 6HR X80%= 600 HRS
PLANT 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 GARMENTS
SAM / GARMENT = 15 MINS
ANSWER : REQUIRED CAPACITY TOTAL HOURS : 30,000 X 15 SAM/PC / 60 = 7500 HRS
DAYS REQUIRED TO COMPLETE ORDER: 7500 HRS
-------------- = 12.5 DAYS
600 HRS/DAY
THANK YOU
