Sum of average
1. Average time (in minute) = ……………………………………… ÷ 60
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑜𝑏𝑠𝑒𝑟𝑣𝑎𝑡𝑖𝑜𝑛
2. Normal time = Average cycle time × Rating.
3. SMV =Observe time × Rating + Allowance.
𝑇𝑜𝑡𝑎𝑙 𝑜𝑢𝑡𝑝𝑢𝑡 ×O𝑝𝑒𝑟𝑎𝑡𝑖𝑜𝑛 𝑆𝑀𝑉
4. Individual OP efficiency = ……………………………………….. ×100
𝑇𝑜𝑡𝑎𝑙 𝑤𝑜𝑟𝑘𝑖𝑛𝑔 𝑚𝑖𝑛𝑢𝑡𝑒
𝑇𝑜𝑡𝑎𝑙 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 × 𝑆𝑀𝑉
5. Efficiency % = ………………………………………………… ×100
𝑇𝑜𝑡𝑎𝑙 𝑤𝑜𝑟𝑘𝑖𝑛𝑔 𝑚𝑖𝑛𝑢𝑡𝑒 ×𝑇𝑜𝑡𝑎𝑙 𝑚𝑎𝑛𝑝𝑜𝑤𝑒𝑟
𝑇𝑜𝑡𝑎𝑙 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝑋 𝑆𝑀𝑉
6. Performance = ……………………………………..............……………. X 100
(𝑀𝑎𝑛𝑝𝑜𝑤𝑒𝑟 ×𝑇𝑜𝑡𝑎𝑙 𝑤𝑜𝑟𝑘𝑖𝑛𝑔 𝑚𝑖𝑛𝑢𝑡𝑒)−𝐿𝑜𝑠𝑠 𝑡𝑖𝑚𝑒
𝐷𝑢𝑟𝑖𝑛𝑔 𝑖𝑛𝑡𝑒𝑟𝑣𝑒𝑛𝑡𝑖𝑜𝑛 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦−𝐵𝑎𝑠𝑒 𝑙𝑖𝑛𝑒 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦
7. Efficiency Improvement = ………………………………………………........………… x 100
𝐵𝑎𝑠𝑒 𝑙𝑖𝑛𝑒 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦
8. Total labor cost saved per line = Extra minute produce × cost per SAM.
60
9. Worker potential production per hour = …………………………
𝐵𝑎𝑠𝑖𝑐 𝑚𝑖𝑛𝑢𝑡𝑒 𝑣𝑎𝑙𝑢𝑒
60
10. Individual worker target per hour = ……. × 𝑊𝑎𝑛𝑡𝑒𝑑 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦
𝑆𝑀𝑉
60
11. Line target per hour = ………… ×(𝑀𝑎𝑛𝑝𝑜𝑤𝑒𝑟 ×𝑊𝑎𝑛𝑡𝑒𝑑 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦)
𝑆𝑀𝑉
𝑇𝑜𝑡𝑎𝑙 𝑛𝑜 𝑜𝑓 𝑑𝑒𝑓𝑒𝑐𝑡 𝑢𝑛𝑖𝑡
12. Defect of hundred unit (DHU) = ……………………………… x 100
𝑇𝑜𝑡𝑎𝑙 𝑖𝑛𝑠𝑝𝑒𝑐𝑡𝑖𝑜𝑛 𝑢𝑛𝑖𝑡
𝑇𝑜𝑡𝑎𝑙 𝑛𝑜 𝑜𝑓 𝑑𝑒𝑓𝑒𝑐𝑡 𝑢𝑛𝑖𝑡
13. Defective % = …………………………………… x 100
𝑇𝑜𝑡𝑎𝑙 𝑖𝑛𝑠𝑝𝑒𝑐𝑡𝑖𝑜𝑛 𝑢𝑛𝑖𝑡
𝑇𝑜𝑡𝑎𝑙 𝑜𝑢𝑡𝑝𝑢𝑡
14. Productivity each person per hour = …………………………………………. x 100
𝑇𝑜𝑡𝑎𝑙 𝑤𝑜𝑟𝑘𝑒𝑟 ×𝑇𝑜𝑡𝑎𝑙 𝑤𝑜𝑟𝑘𝑖𝑛𝑔 𝑚𝑖𝑛𝑢𝑡𝑒
𝑇𝑜𝑡𝑎𝑙 𝑢𝑛𝑖𝑡𝑠 𝑝𝑟𝑜𝑑𝑢𝑐𝑒 𝑏𝑦 𝑡ℎ𝑒 𝑙𝑖𝑛𝑒
15. Machine productivity = ………………..............................………………………..
𝑇𝑜𝑡𝑎𝑙 𝑛𝑜 𝑜𝑓 𝑚𝑎𝑐ℎ𝑖𝑒𝑛 𝑢𝑠𝑒 𝑡𝑜 𝑝𝑟𝑜𝑑𝑢𝑐𝑒 𝑡ℎ𝑜𝑠𝑒 𝑔𝑎𝑟𝑚𝑒𝑛𝑡𝑠
𝑇𝑜𝑡𝑎𝑙 𝑆𝑀𝑉
16. Basic pitch time = ………………………………
𝑇𝑜𝑡𝑎𝑙 𝑚𝑎𝑛𝑝𝑜𝑤𝑒𝑟
𝐵𝑎𝑠𝑖𝑐 𝑝𝑖𝑡𝑐ℎ 𝑡𝑖𝑚𝑒
17. Upper control limit = …………………………………………
𝑊𝑎𝑛𝑡𝑒𝑑 𝑜𝑟g𝑎𝑛𝑖𝑧𝑎𝑡𝑖𝑜𝑛 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦
18. Lower control limit = (Basic pitch time × 2) – 𝑈𝑝𝑝𝑒𝑟 𝑐𝑜𝑛𝑡𝑟𝑜𝑙 𝑙𝑖𝑚𝑖𝑡
𝑇𝑜𝑡𝑎𝑙 𝑐𝑢𝑡 𝑞𝑢𝑎𝑛𝑡𝑖𝑡𝑦 - 𝑇𝑜𝑡𝑎𝑙 𝑠ℎ𝑖𝑝 𝑞𝑢𝑎𝑛𝑡𝑖𝑡𝑦
19. Cut of ship loss % = …………………………………...……..…… ×100
𝑇𝑜𝑡𝑎𝑙 𝑐𝑢𝑡 𝑞𝑢𝑎𝑛𝑡𝑖𝑡𝑦
𝑇𝑜𝑡𝑎𝑙 𝑠ℎ𝑖𝑝𝑝𝑒𝑑 𝑞𝑢𝑎n𝑡𝑖𝑡𝑦
20. Cut of ship ratio = ………………………………………. ×100
𝑇𝑜𝑡𝑎𝑙 𝑐𝑢𝑡 𝑞𝑢𝑎𝑛𝑡𝑖𝑡𝑦
𝑁𝑒𝑤 𝑐𝑢𝑡 𝑡𝑜 𝑠ℎ𝑖𝑝 𝑟𝑎𝑡𝑖𝑜−𝐵𝑎𝑠𝑒 𝑙𝑖𝑛𝑒 𝑟𝑎𝑡𝑖𝑜
21. Cut of ship ratio improvement % = …………………..…………………………..×100
𝐵𝑎𝑠𝑒 𝑙𝑖𝑛𝑒 𝑟𝑎𝑡𝑖𝑜
𝑇𝑜𝑡𝑎𝑙 𝑠ℎ𝑖𝑝 𝑞𝑢𝑎𝑛𝑡𝑖𝑡𝑦
22. Receive to ship ratio = …………........................………………………… ×100
𝑇𝑜𝑡𝑎𝑙 𝑓𝑎𝑏𝑟𝑖𝑐 𝑟𝑒𝑐𝑒𝑖𝑣𝑒 𝑓𝑜𝑟 𝑡ℎ𝑒 𝑜𝑟𝑑𝑒𝑟 (𝑆𝑞.𝑦𝑑𝑠)
23. Total financial saving = Number of extra pieces shipped × Average FOB
𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝑒𝑥𝑝e𝑛𝑑𝑖𝑡𝑢𝑟𝑒 𝑜𝑓 𝑡ℎ𝑒 𝑓𝑎𝑐𝑡𝑜𝑟𝑦
24. Cost Per Minute (CPM) = …………………………............………………..
𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝑃𝑟𝑜𝑑𝑢𝑐𝑒 𝑡𝑖𝑚𝑒 (𝑀𝑜𝑛𝑡ℎ𝑙𝑦)
25. Cost of Manufacture (CM) = SMV × CPM
𝑇𝑜𝑡𝑎𝑙 𝑜𝑢𝑡𝑝𝑢𝑡 ×𝐶𝑀 𝑝𝑒𝑟 𝑔𝑎𝑟𝑚𝑒𝑛𝑡𝑠
26. CM earned per person per hour = ………………….....………………………….
𝑇𝑜𝑡𝑎𝑙 𝑤𝑜𝑟𝑘𝑒𝑟 ×𝑇𝑜𝑡𝑎𝑙 𝑤𝑜𝑟𝑘𝑖𝑛𝑔 𝑚𝑖𝑛𝑢𝑡𝑒
27. Monetary Loss due to cut ship loss in month = (Total number of produced garments
in month × cut to ship loss percentage for a month × Average FOB of the style)
28. Monetary Loss due to cut ship loss in style wise = (Total number of produced
garments in the style × cut to ship loss percentage for a month × Average FOB of the style)
𝑇𝑜𝑡𝑎𝑙 𝑚𝑎𝑛𝑝𝑜𝑤𝑒𝑟
29. Man & machine ratio = ……………………………………
𝑇𝑜𝑡𝑎𝑙 𝑚𝑎𝑐ℎ𝑖𝑛𝑒
𝑇𝑜𝑡𝑎𝑙 𝑛𝑜 𝑜𝑓 𝑎𝑢𝑑𝑖𝑡 𝑓𝑎𝑖𝑙
30. Audit fail % = ………………………………….×100
𝑇𝑜𝑡𝑎𝑙 𝑛𝑜 𝑜𝑓 𝑎𝑢𝑑𝑖𝑡
31. Earned minute = Total production X SAM
𝑇𝑜𝑡𝑎𝑙 ℎ𝑒𝑎𝑑𝑐𝑜𝑢𝑛𝑡−𝑁𝑜 𝑜𝑓 𝑚𝑎𝑐ℎ𝑖𝑛𝑒 𝑜𝑝𝑒𝑟𝑎𝑡𝑜𝑟𝑠
32. Factory direct & indirect ratio = …………………………………………………….
𝑇𝑜𝑡𝑎𝑙 𝑛𝑜 𝑜𝑓 𝑜𝑝𝑒𝑟𝑎𝑡𝑜𝑟𝑠
𝑇𝑜𝑡𝑎𝑙 𝑠𝑎𝑙𝑎𝑟𝑦 𝑜𝑓 𝑡ℎ𝑒 𝑙𝑎𝑏𝑜𝑟 𝑖𝑛 𝑡ℎ𝑒 𝑚𝑜𝑛𝑡ℎ
33. Labor cost per minute = ……………........……………………………………….
𝑇𝑜𝑡𝑎𝑙 𝑆𝐴𝑀 𝑝𝑟𝑜𝑑𝑢𝑐𝑒 𝑏𝑦 𝑡ℎ𝑜𝑠𝑒 𝑙𝑎𝑏𝑜𝑟𝑠 𝑖𝑛 𝑡ℎ𝑎𝑡 𝑚𝑜𝑛𝑡ℎ
𝑁𝑜 𝑜𝑓 𝑚𝑎𝑐ℎ𝑖𝑛𝑒 𝑎𝑠𝑠𝑖𝑔𝑛𝑒𝑑 ×𝐻𝑜𝑢𝑟𝑙𝑦 𝑡𝑎𝑟𝑔𝑒𝑡 𝑞𝑡y
34. Estimated production per hour = …………………………………………………………….
𝐶𝑎𝑙𝑐𝑢𝑙𝑎𝑡𝑒𝑑 𝑛𝑜 𝑜𝑓 𝑚𝑎𝑐ℎ𝑖𝑛𝑒𝑠
𝑇𝑜𝑡𝑎𝑙 𝑚𝑖𝑛𝑢𝑡𝑒 𝑖𝑛 𝑎 𝑠ℎ𝑖𝑓𝑡 ×𝐿𝑖𝑛𝑒 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦
35. Estimated machine productivity = ………………………………………………………..
𝐺𝑎𝑟𝑚𝑒𝑛𝑡𝑠 𝑆𝑀𝑉
𝑊𝑜𝑟𝑘𝑒𝑟 𝑝𝑜𝑡𝑒𝑛𝑡𝑖𝑎𝑙 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝑃.𝐻 - 𝐶𝑢𝑟𝑟𝑒𝑛𝑡 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝑝𝑐𝑠 𝑃.𝐻
36. Productivity Gap % =
………………….……………..................………………………… ×100
𝐶𝑢𝑟𝑟𝑒𝑛𝑡 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝑝𝑐𝑠 𝑝𝑒𝑟 ℎ𝑜𝑢𝑟
1. Standard Pitch Time (S.P.T) = Basic Pitch Time (B.P.T) + Allowances (%)
▪ GSD = (Man power * Work hour) / Target
▪ SMV = Basic time + (Basic time * Allowance)
▪ Basic time = Observed time * Rating
▪ Observed time = Total Cycle time / No of cycle
▪ Rating = (Observed Rating * Standard rating) / Standard rating
▪ Efficiency = (Earn minute * Available minute) * 100
▪ Earn minute = No of Pc’s (Production) * Garments SMV
▪ Available minute = Work hour * Manpower
▪ Organization Efficiency = (Basic pis time / Bottle neck time) * 100
▪ Basic pis time = Total GMT SMV / Total Manpower
▪ UCL = Basic pis time / Organization Efficiency
▪ LCL = 2 * Basic pis time – UCL
▪ Capacity = 60 / Capacity time in minute
▪ Cycle Time = 60 / Team target
▪ Capacity Achievable = Capacity * Balance
▪ Daily output = Work hour / SMV
▪ Factory capacity = (Work hour / SMV) * Total worker * Working day * Efficiency
▪ CPM = (Total over head cost of the month / No of SMV earners * Work minutes)
*Efficiency
▪ Required no of operator = Target daily output / Daily output per operator
Example:
1. Efficiency = Output/Input
= (SMV*Product Quantity) / (Worker*Working Hour*60)
= [(38.50*700) / (60*10*60)]*100
= 74% (Line Efficiency)
Here,
SMV=38.50
Working hour=10
No. of worker=60
2. Target/hour = (60/SMV)*Efficiency%
= (60/0.85)*70%
= 50 pcs/hour
Here,
SMV=0.85
Efficiency=70%
3. Target/line = [(No of worker*working hour*60)/SMV]*Efficiency%
= [(75*10*60)/23.5]*60%
= 1150 pcs
Here,
No of workers=75
Working hours=10
SMV=23.5
Efficiency=60%
4. Required days for the schedule = Total order quantity/Average target
= 50000/2000
=25
Here,
Average target=2000
Order quantity=50000
5. CM of garments= (Total Production)/(no of worker*work hour)
= 250000/(1500*10)
=1.66 BDT
Here,
Total Production=250000
No of workers= 1500
6. Factory capacity = [(Work hour*total workers*working day*60)/SMV]*Efficiency
= [(10*1500*26*60)/14.13]*55%
= 828025 pcs/month
7. Line GSD/day = (Manpower*work hour)/target
= (50*10*60)/900
= 33