Production Capacity Calculation of a Garment Factory
Shubham Anil Jain
Sr. Consultant
Cent Edge Solutions LLP, Bangalore, India
Email: shubhamajain125@gmail.com
Introduction:
Generally, the production capacity in any manufacturing industry is the number of pieces the employees can manufacture in a given period of time, simply like an hour, day or week. When it comes to the garment industry, production capacity is considered as one of the prominent factor which is been used for merchant for the selection by the buyers. So it is an important criteria that the marketing as well as planning department must be aware about the production capacity of the production lines. So, basically the production capability of a garment factory is particularly defined by means of total number of machines in the factory or number of pieces the factory can manufacture on a daily basis for the given product style.
Basically, it is seen that the total numbers of machines in an industry simply remain the same for a specified period of time. But an industry can produce multiple styles of product during the specified season. As per the requirement of the particular style, the machinery needs can be changed and the average production in each style may change. So, to calculate the daily production capacity in terms of number of pieces, the basic information related to factory capacity in terms of hours, SAM of the product and line efficiency is required.
How to Calculate Production Capacity of a Garment Factory?
So, basically the production capacity of a garment factory is completely related with machine (Hr) capacity, line efficiency of the factory and importantly on the standard allowed minute (SAM) of produced item. For getting proper production capacity of a garment factory, it is the role of an industrial engineer to confirm accurate cutting room capacity, finishing room capacity as well as washing capacity also.
So, following are the steps to calculate production capacity:
1. To calculate the factory capacity (in hours):
Initially find out how many total machines does the factory has and how many hours factory runs particularly in a day. For example, assuming,
Total number of machines = 500
Shift hours per day = 8 hours
So total factory capacity (in hours) = 500*8 hours = 4000 hours
2. To Calculate Product SAM (SAM):
Now, create a list of the product category that the factory is manufacturing and simply get the standard minutes (SAM) of all products you make from work-study, time study methods by engineers. Suppose if you don’t have product SAM then go for calculating the SAM. Now here, assuming that the factory is producing a shirt and its SAM is 23 minutes.
3. Factory Average Efficiency:
Now when it comes to average efficiency, this data is simply collected from the industrial engineer. Or one can also calculate it with the help of historical data. Here, assuming that the average line efficiency is 75%.
4. Calculating of production capacity (in pieces):
Now, once you are ready with the above information, simply use the following formula to calculate production capacity.
Production capacity (in pieces) = (Capacity in hours*60/product SAM)*line efficiency
For Example: Assume a factory has 10 sewing lines and each line has 50 machines. Total 500 machines and the working shift is 8 hours per day. The total factory capacity per day is 4000 hours (500 machines * 8 hours). If the factory is producing only one style (Shirt) of SAM 23 minutes and used all 500 machines daily production capacity at 75%.
= (4000*60/23)*75% Pieces
= (4000*60*75) / (23*100) Pieces
= (18000000/2300) Pieces
= 7826 Pieces
So, the production capacity of a factory is 7826 pieces per day.
It is generally observed that the production (capacity) planning is basically done based on sewing capacity. But having a good knowledge of the capacity in many of the other processes (internal or external) is also very necessary. Otherwise, the planner may sometimes fail to meet the dead line. Again in many other departments of garment industry like cutting room capacity, Finishing room capacity, Washing Capacity and capacity of the value-added jobs, can be calculated in the same way.
Conclusion:
So, overall to calculate the production capacity of a garment factory is an important step specifically in planning and optimizing manufacturing operations. So by considering various factors like available working hours, individual operator/line efficiency, and standard minutes per garment, garment producers can simply go for estimating the maximum output that can be achieved within a given time period. So, basically it is very necessary to estimates the production capacity calculations and it can be simply influenced by factors like machine breakdowns, material availability, and variability in workforce.
References:
- 25/06/2023, How to Calculate Production Capacity of a Garment Factory https://www.textileblog.com/how-to-calculate-production-capacity-of-a-garment-factory/
- Prasanta Sarkar, September 10, 2018, How to Calculate Production Capacity of a Factory? https://www.onlineclothingstudy.com/2011/11/how-to-calculate-production-capacity-of.html
- Mohiuddin Ahmed, January 16, 2020, How to Calculate Production Capacity of a Factory? https://www.onlineapparelstudy.com/2020/01/How-to-Calculate-Production-Capacity-of-a-Factory.html
- How to Estimate Production Capacity of a Garment Factory? https://garmentsmerchandising.com/how-to-estimate-production-capacity-of-a-garment-factory/
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- 15 Ways to Improve Productivity in Garment Production
- Productivity of Garment Industry: Various Ways to Improve It
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Founder & Editor of Textile Learner. He is a Textile Consultant, Blogger & Entrepreneur. Mr. Kiron is working as a textile consultant in several local and international companies. He is also a contributor of Wikipedia.
