Hello today I’m presenting to you operation bulletin for model no 7091.

So first we have to create a list of operations by making part wise sections that is cotton wool parts then
back, seat & then arm.

And at the last we have preparatory section in which we have list of operations which includes
operations involves making ready trims which is required to complete this model for example zipper or
tension rod cutting & marking as per required measurement.

In next column we have freq – freq indicates the no of particular operation in single set.

Next we have machine column – includes name of machine used for particular operation

After that we have to calculate Basic time

So for calculate basic time we need to take 10 readings on stopwatch of the each operation

Here is the example of one of the operation where you can see 10 readings in second of mentioned
operation.

Then we have to calculate average of same and at the last we have to convert it into minutes.

So here we have basic time of particular operation.

After calculating basic time for each operation we have to add allowances in basic time to calculate
SAM.

SAM means standard allocated minutes.

There are 3 types of allowances we will add in basic time.

1st is Personal fatigue delay allowance – which we add for labors personal needs, fatigue & unavoidable
delays.

2nd is machine delay allowance – which is for machine breakdown & settings.

3rd is bundle handling time - for tying & untying of bundles.

So we add here PFD allowance 7.5% which is standard %

Then we add machine delay allowance 7.5% for single needle lockstitch machine. It is variable depend
upon machine. Depending upon complexity & difficulty of machine.

This allowance will not be added to manual operations which do not include any type of machine in it.

And at the last we will add BHT allowance 2.5%

So after adding all 3 allowances in to the basic time we will get SAM that is standard allocated minutes
for each operation.
After calculating SAM for all operations, we have to add more 10% allowance in to total SAM which will
belong to whole production line, to cover time loss occurs due to balancing of different operations with
different time or SAM.

So now we have total SAM for one full set of particular model.

We will divide it into 2 categories, which is machine SAM & manual SAM.

Machine SAM includes SAM of operations which includes machine & manual SAM includes SAM of
operations which are without machine or performed manually.

And then we have total SAM at the end.

Next we have no. of workstation – which shows us no. of operator we need for completing the target of
particular operation as per total SAM of model on peak efficiency & with available manpower we put in
production line.

After that we have balanced workstation – which shows no. of operator which we actually put on
particular operation.

So now we have difference between no. of operator we need to perform particular operation as per
total production line target & no. of operator we actually put on particular operation.

So we need to balance this operator in other operation to fulfill its ideal time remains after producing
target of given operation.

And column next to it will show us no. of operation on which particular operation is balanced if any.
So after calculating SAM we can calculate various percentage of productivity of each stage to monitor
analyze & improve the productivity.

Let’s see how we will calculate the same.

So first is individual operator efficiency

First we have no. of pieces produced by operator of given operation.

Second we have SAM of particular operation

Next to that we have shift time in which production is done.

After that we have to calculate available SAM that is minutes available in hand to perform the given
operation. That is shift time 8 hours means 480 minutes.

After that we can calculate produced SAM that is no. of minutes operator actually produced.

That means no. of pieces multiplied by SAM of particular operation that here we have 392 minutes.

So for efficiency we have to divide produced SAM by available SAM.

And we will get efficiency of the particular operator. As you can see here 81.67 %

We can also calculate each models part wise efficiency separately.

Let’s see how we can calculate the same.

So here we first have model no. that is for example 7091, next to that we have section name which is
ARM section, Back & Seat section.

Then we have SAM for each part separately, and then production of the each part in shift.

Next we have no. of operators used for production.

And again we have available SAM which is no. of operators multiplied by shift time in minutes.

Produced SAM which is no. of pieces produced multiply by SAM of relative PART.

So again here formula for efficiency is same that is Produced SAM divided by Available SAM.
Next we will see how we can calculate efficiency for total production section produced different models
at same shift.