CAPACITY

IN
APPAREL
INDUSTRY

SunilTalekar
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
 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.
 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
Exercise: sewing machine threading exercise, to calculate SM in SOFT
 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.
 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.
 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.
 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.
 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 .
 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.
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?
 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.
 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 .
 Monitor daily production delays.
QUESTION ONE.

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
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:___________________
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 Machine type Machine 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? ______________
Equipment requirement : O/L = 19

Production output target = 1000 units per day.

Indirect labor:

Operation SAM Prod/day Manpower 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 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
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 Machine Type Machine 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