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Basic IE Formulas

This document outlines 18 formulas used in the garment industry for production planning and analysis. Some key formulas calculate daily line targets based on minutes, operators, and efficiency; individual operator targets and efficiency; line efficiency; machine and labor productivity; work in process; standard times; machine utilization; costs per minute and unit; man to machine ratios; samples per minute; operator hourly and daily capacities; defects per hundred units; pitch time; and takt time. The formulas provide a way to measure and optimize important metrics in garment production lines and processes.

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445 views

Basic IE Formulas

This document outlines 18 formulas used in the garment industry for production planning and analysis. Some key formulas calculate daily line targets based on minutes, operators, and efficiency; individual operator targets and efficiency; line efficiency; machine and labor productivity; work in process; standard times; machine utilization; costs per minute and unit; man to machine ratios; samples per minute; operator hourly and daily capacities; defects per hundred units; pitch time; and takt time. The formulas provide a way to measure and optimize important metrics in garment production lines and processes.

Uploaded by

wjgbrrrxmc
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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Basic IE Formulas used in garment industry.

Formula#1:
Daily Line Target = (Total working minutes in a day X No. of operators in a line X Line eff%)/Garment SAM

Formula#2:
Individual operator target = (Total working minutes in a day X line efficiency %)/Operation SAM

Formula#3:
Individual operator Efficiency% = (units produced X operation SAM X 100)/Total minutes worked

Formula#4:
Line Efficiency% = (Line output X garment SAM X 100)/(Number of operators X minute worked in a day)

Formula#5:
Machine Productivity: Line output / No. of machine used

Formula#6:
Labour Productivity = Line output / No. of total manpower (operators +helpers)

Formula#7:
Line WIP (work in process) = Total pieces loaded in the line – Total output.

Formula#8:
Standard Time = (Observed time X observed rating) + Allowances
Allowances – Relaxation allowance, contingency allowance

Formula#9:
Machine utilization% = (Actual Machine running Time X 100) / Time available

Formula#10:
Cost per minute = Total cost incurred in labour / Total available working minute in a day X no. of labours

Formula#11:
Production Cost per unit = Total cost incurred in production in a day/ no. of garment produced in a day

Formula#12:
Man to Machine ratio = Total manpower of the factory / Total no. of sewing machines (utilized)

Formula#13:
SAM= Basic time+ 10% (bundle allowance) + 20% (machine & PFD allowance)

Formula#14:
Operator Hourly Capacity/Target (1 hour= 60 minutes) = 60/SAM
Operator Daily Capacity/Target (8 hours= 480 minutes) = 480/SAM
Formula#15:
Daily Line Capacity= Total no. of Operators in the line * 480 minutes (8 hours)/ SAM of the Garment.

Formula#16:
Defects per hundred units = (Total defects found * 100)/Total garments inspected

Formula#17:
Pitch Time = Garment SAM/No. of operations.

Formula#18:
Net available time / Customer demand
= 4500 minutes per shift (10 operator’s total man-minutes)
= 500 pieces per shift
Takt time = (4500÷500) = 9 minutes per piece

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