Industrial Engineering

Basic Garments Terminology

Some Basic Terms

 Production
 Productivity
 Capacity
 Capacity Utilization / Capacity Gap
 Efficiency
Production
Production is any process or procedure developed to transform a set of input
elements like men, materials, capital, information and energy into a specific
set of output elements like finished products and services in proper quantity
and quality, thus achieving the objective of an enterprise.

The essence of production is the creation of goods may be by transformation

of raw materials or assembling so many small parts (Ex - TV, Vehicle etc).

There are four factors of production namely:

1. Nature ( Land and other natural resources)

2. Labor (human efforts)
3. Capital (Factory buildings, machinery, tools, raw materials etc)
4. Enterprise (activity that organizes other factors of production into an
operating unit).
Production

Materials

Plant and Goods and

Men
Facilities Services

Energy

Production
Inputs Outputs
Process

Model Showing Production Process

Cost Effective Production
 Production

 No. of pcs. or Units produced

 Out Put in a given period of time
Example
Unit-A produces- 500 Units/Day
Unit-B produces-600 Units/Day
Production/day of Unit-B is more than that of Unit-A
( Out put refers to goods or services produced)
Production figures don’t give idea about

Inputs - in terms of resources used/consumed to produce the

Out put-
 Man
 Machinery
 Value
 Area/Space
 Man Hrs. or Machine Hrs.
 So, How one will know whether
Production is economical/beneficial or
not?
Productivity

Relationship Between Output and Input

Productivity= Output/Input

The O/P of the plant or sections or departments

within the plan could be-
Qty. of Fabric inspected
No. of panels cut
No. of garments stitched or Ironed
No. of Garments washed or packed
Standard Definition

 Productivity denotes the productiveness of the factors of

production.

 In simple words - Productivity is concerned with the efficient

utilization of resources (Inputs) in Producing goods or
services (Outputs)
Standard Definition

 Productivity refers to the efficiency of the production system. It is an

indicator of how well the factors of production land, capital, labor
and energy) are utilized.

 It may also be defined as human effort to produce more and more

with less and less inputs of resources as a result of which the
benefits of production may be distributed more equally among
maximum number of people.

 For example, the yield of 15 bags of paddy in one acre of land with
some labor and capital is known as production. By improved method
of cultivation but with same labor and capital, the production of say
20-30 bags of paddy is productivity improvement.
Productivity

  Plant A Plant B
No. of Workers 200 300
No. of items produced per unit of 10 20
time
     
Productivity 10/200 20/300
  0.05 0.067
Productivity
Productivity
Productivity
 Purpose to Increase Productivity
   
To produce good earnings(profit)
To clear the debts and loans acquired from
For Management different sources
To sell more
To stand better in the market
   
Higher wages
Better working conditions
For Workers
Higher standard of living
Job security and satisfaction
   
Reduced price of the articles
For Customers Better quality and value
More Satisfaction to customers
   
Provides Greater National Wealth
Increases per capita income
Improves Standard of Living
For Nation Better utilization of resources of the nation
Helps in expansion of International Market with
the help of standardization and good quality
product
Productivity and Standard of Living
 Each man must earn to pay for the services (hygiene, security and education)
and to obtain goods (food, shelter and clothing) for himself and his family.

 If the quantity of goods and services produced by any country is higher, the
standard of living of the citizens of that country is also higher.

 We can have more and affordable food by increasing productivity of agriculture.

 By increasing productivity of industry, we can provide more and inexpensive

clothing.

 Higher productivity means that more is produced at same expenditure of

resources.

 Efficient utilization of resources means cost reduction and savings.

Relationship between Productivity
and Standard of Living
Total and Partial Productivity

Total productivity is the ratio of total Output to the sum of all Input factors.

 A total productivity measure reflects the joint impact of all the inputs in
producing the output.
 Total productivity measure doesn’t tell the management which of its
products or services is causing a decline or growth, nor does it which
particular inputs- workers, material, capital, energy or other expenses-
are being utilized inefficiently.
 In simple words- Data analysis is relatively difficult.
Partial Productivity

Partial productivity is the ration of out put to one class of input.

For example-
 Labor productivity- Ration of output to the Labor productivity.
 Partial productivity measures are easy to understand, use and
compute.
 It’s a good diagnostic tool for pinpointing improvement areas.
 But at the same time it has some disadvantages also - If used
alone-can be misleading and may lead to costly mistakes.
 It can’t be used to explain overall cost increase.
Productivity Improvement

A TASK have below components-

1. Basic Work Content- the amount of work “contained in” a job.
2. Excess Work Content-
 Work content added by defects in design or specification of the
product
 Work content added by inefficient methods of manufacturing
3. Ineffective time
 Due to the short-comings of management
 Ineffective time within the control of the worker
 Productivity Improvement

The factors- Excess work content and Ineffective time do reduce the
efficiency or can be said as non productive factors.

Basic Work Content is the main component of the task for which
resources are utilized.

High productivity is achieved where the Excess Work Content and

Ineffective Time for a job are small, or have been eliminated, and the
Basic Work Content is a high percentage of the Total Time for the job
How productivity is lost?

 Annual Labor Turn over

 Absenteeism
 Methods ineffectiveness
 Avg. Factory performance
 Repairs and Rejects ( Quality issues) - Not RIGHT First Time…
 Balancing losses
 Machine delay/idle times
 Unmeasured work
Some Questions

 Who will tell productivity is low or high?

 Comparing it to the benchmarks?
 How it will be judged?
 How to increase the productivity?
For Higher Productivity

ME+EM+ME+EM=HP+EQC

Modern High
Motivated
Equipments Productivity
Employees

Enlightened
Management
Effective
Engineered
Quality Control
Methods
Capacity

 Maximum possible out put of goods or services @ given

resources @ ideal / std. conditions
 This is purely a mathematical figure.
Capacity Utilization

 The actual ability to produce/deliver goods or services at given

resources and working conditions.

 Targets are set always by considering Capacity Utilization only.

 Capacity Gap- The diff. between Capacity and Capacity

Utilization.
Efficiency

 How good or bad we perform against the Target set.

 How efficient or successful we are to achieve the Target

 The target is expressed as a time per garment or a required level of

production.

 Targets are normally set at a performance level of 100%, and

therefore if an operator reaches his / her target production, then his /
her efficiency would be 100%
Efficiency

 Efficiency= (Time Allowed / Time Taken)*100

 Efficiency= (Achieved Production/Target Production)*100
Productivity and Efficiency

 Productivity and efficiency are the primary performance measures in

garment production. 

 Productivity is the ratio of output (products or services) and input

(labour, machine, man-hours).

 Productivity can be measured as labour productivity, machine

productivity, and value productivity for a production line or of a whole
factory.

 For example – Labour productivity is defined as output (in pieces) per

labour (direct +indirect) in a given time frame.

 Example of labour productivity of a Shirt line is 10 pieces per day per

labour on 8 hour shift. 
Productivity and Efficiency

 Efficiency is the ratio of total minutes produced and total minutes

worked by an individual operator, or a line.

 Efficiency is expressed in percentage.

 For example, stitching line efficiency of a typical stitching line is 56%. 

 Productivity and Efficiency

 Productivity formula:

Productivity = Output / Input

Labour productivity = (Total garments produced / Number of labours involved) in
 given time frame
Machine productivity = (Total garments produced / total number of machine
utilized)

 Efficiency Formula:

Efficiency = (Total SAH produced / Total hours worked)*100

Efficiency = (Total Minute produced / (Total hours worked*60))*100
Where, Total minutes produced = (Number of pieces produced * Garment SAM) 
Total minutes worked = (Number of workers * shift hours * 60)
Productivity and Efficiency

 Efficiency is measured for individual operators, for each lines and

overall factory efficiency.

 In garment production labour productivity is presented as number

of pieces produced per labour per shift.

 Labour productivity of the same line with same number of labour

for two different products (e.g. a T-shirt and a Polo shirt) may be
different. But Line efficiency can be same in both products.

 To calculate line efficiency we must have garment SAM (standard

minutes) for your products. On the other hand we don’t need SAM
to calculate labour productivity.
Productivity and Efficiency

A line of 35 operators and 5 helpers produced 400 pieces in day of 8 hours

shift. Garment SAM is 25 minutes. Considering helpers SAM is included in
garment SAM.

Total labour input (A) = 35+5 = 40 labours

Total production (B) = 400 pieces of garments
Total SAM produced (C) = 400 pieces * 25 minutes = 10000 minutes
Total Minutes attended (worked) by all workers (D) = 40 workers * 8 hours shift * 60
= (40 *8 *60) minutes
Labour productivity = B/A =400/40 = 10 pieces per labour per shift
Line Efficiency = (C/D)*100 = (10000 *100) / (40 * 8 * 60)
= (1000000 /19,200) % = 52.08%

Line Efficiency (excluding helper) is 59.52%. This is derived from (400*25*100)/

(35*8*60)
Productivity and Efficiency

 Productivity is product specific measure.

 When we compare our factory’s productivity with another factory’s

productivity, we have to check if both factories are making same
product.

 If different products are made by the factories, we can do

productivity comparison by converting productivity of one product
to equivalent SAM of the second product.

 Factories those don’t have industrial engineering department and

don’t calculate garment SAM are not in position to measure accurate
line efficiency.

 For them productivity measure is one that they can follow.

Thank You