Last Updated on June 7, 2026
Sewing Production Calculations in Garment Industry
R.S. Balakumar
Associate Professor
Dept of Fashion Design & Arts
Hindustan University, Chennai, India
Email: [email protected]
Sewing Production Calculations
Sewing production calculations are essential for efficient planning and control in the garment manufacturing industry. Accurate calculations help industrial engineers and production managers determine machine requirements, manpower allocation, production capacity, floor space needs, and annual output targets. These calculations support better line balancing, resource utilization, and productivity improvement while reducing production bottlenecks and operational costs. In this article, we will discuss the most important sewing production calculations used in garment factories, along with practical examples for easy understanding.
I have already published some articles on sewing operation, sewing faults and defects, sewing machine maintenance, questions and answers on sewing for students. In this article I will discuss on sewing production calculations in garment industry.
(1) To calculate the number of machine necessary for daily production quantity in each process.
The number of sewing machines necessary for each process,
…..Time for each process X daily production quantity
= ………………………………………………………….………………………………
…………………….Work time per day
Example: For dart sewing
Process time …………………………..0.76 min.
Work time per shift …………………480 min.
Production quantity per shift….400 pcs.
……………………………………………………………………………………0.76 X 400
So, The number of machines necessary for each process = …………………
……………………………………………………………………………………….480
The number machine necessary for sewing darts = 0.63 = 1 machine (ANS)
(2) The number of the machine you need will be calculated by applying the value obtained in (1) to the configuration (process composition).
In each park and each kind of machine. When you establish process composition, consideration to the layout which allows the works in process to run smoothly between lines must be taken.
(3) Calculation method of the number of the required machine according to the different of production quantity per shift or the number of persons
The number of required machine should be originally calculated in the way as above-stated in (1).
But there is a simplified calculation method by using MACHNE LIST and BASIC DATA described in this document.
(4) Calculation method of the number of required machines according to the difference of production quantity per shift
The number of required machine,
…………………………………………………..Production quantity per shift after change
= The number of each machine X ………………………………………………………………………
…………………………………………………………….Production quantity per shift
Example:
The number of DDL-555ON-7 –WB/CP230/AK-85…………………8 machines
Production quantity per shift …………………………………………200 pcs.
Production quantity per shift after change…………………………….120 pcs.
……………………………………………………………………….120 pcs
The number of required machine = 8 machine X …………
……………………………………………………………………….200 pcs
= 4.8 = 5 machine (ANS)
(5) Calculation method of the number of required machine according to the difference of persons
The number of required machine,
…………………………………………………The machine of persons per shift after change
= The number of each machine X ………………………………………………………………………..
……………………………………………………………………The number of person
Example:
The number of DDL-555ON-7-WB/CP230/AK-85 …………8 machines
Number of persons per shift ………….………………….45 persons
Number of persons per shift after change……………………100 persons
………………………………………………………………………….100 persons
The number of required machines = 8 machine X ……………………………………
…………………………………………………………………………..45 persons
= 17.7 = 18 machines (ANS)
(6) Calculation method of the production quantity per year according to the different of work days per year. The production quantity per year is calculated on the basis of 280 days per year in this document. When the number of work days per year is different, use the following formula to obtain the production per year.
The production quantity per year,
……………………………………Work days per year after change
= Production per year X …………………………………………………………………
…………………………………………………..280 days
EXAMPLE:
Production quantity per year …………………..……………56,000 PCS.
Work days per year after change ……………………………250 days
…………………………………………………………………………..250 days
The production quantity per year = 56,000 pcs. X …………………..
………………………………………………………………………….280 days
= 50,000 pcs . (ANS)
(7) Method of the number of persons according to the difference of production quantity per shift
…………………………………………………………………Production quantity per shift after change
The number of persons = Number of persons X ………………….…………………..…………..……
…………………………………………………………………………Production quantity per shift
EXAMPLE:
The number of persons ……………………………..45 Persons
Production quantity per shift …………………….500 pcs.
Production quantity per shift after change ………………………850 pcs.
………………………………………………………….850 pcs.
The number of persons = 45 persons X ………………..……
…………………………………………………………500 pcs.
= 76.5 = 77 persons (ANS)
(8) Calculation method of production quantity per shift according to the different of the number of persons
From (formula 2),
Production quantity per shift,
…………………………………………………..The number of persons after change
= Production quantity per shift X ………………………………………………………..
………………………………………………………….The number of persons
EXAMPLE:
Production quantity per shift in BASIC DATA ………………500 pcs.
The number of persons in BASIC DATA ……………………….75 persons
The number of person after change ……………………………100 persons
…………………………………………………………………….100 persons
The production quantity per shift = 500 pcs. X ……………………
…………………………………………………………………….75 persons
= 666.7 = 666 pcs. (ANS)
(9) Simplified sewing production calculations method of the required floor space according to the difference of total number of required equipment
The required floor space = (required floor space per 1 finishing equipment X total number of sewing equipment) + (required floor space per 1 finishing equipment X total number of finishing equipment)
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EXAMPLE:
Required floor space per 1 sewing equipment …………..about 6 m2
Total number of sewing equipment ……………………………187 machines
Required floor space per 1 finishing equipment …………about 10 m2
Total number of finishing equipment ………………………….20 machines
Required floor space,
= (6 m2 /1 machine X 187 machine) + (10 m2 /1 machine X 20 machines)
= 1,322 m2 (ANS)
Practical Considerations When Using Sewing Production Calculations
The formulas presented above provide theoretical requirements. In actual garment factories, machine efficiency, operator skill level, style complexity, learning curve, absenteeism, and machine downtime should also be considered before finalizing manpower and equipment planning.
For new styles, many factories apply an efficiency allowance because actual production output during the initial days is usually lower than the planned target. This helps prevent production bottlenecks and unrealistic capacity planning.
When calculating machine requirements, industrial engineers should also evaluate line balancing conditions. Even if the calculated machine quantity appears sufficient, production flow can still be affected when operations with longer cycle times become bottlenecks.
In floor space planning, additional area should be reserved for work-in-process storage, material handling, inspection activities, operator movement, and future expansion requirements.
Regular review of production calculations is recommended whenever production targets, garment styles, operation breakdowns, or workforce availability change.
Frequently Asked Questions (FAQs)
Q1. How do I calculate sewing line capacity?
Sewing line capacity is generally determined by available working time, operator efficiency, SAM (Standard Allowed Minute), and the number of operators. Capacity calculations should also account for machine downtime and absenteeism to obtain realistic production targets.
Q2. What is the difference between machine requirement and manpower requirement?
Machine requirement determines how many machines are needed for a specific production target, while manpower requirement determines how many operators are needed to achieve that target. Both calculations are interconnected but serve different planning purposes.
Q3. Why is line balancing important in sewing production?
Line balancing helps distribute work evenly among operators and machines. A poorly balanced line creates bottlenecks, increases WIP, and reduces overall productivity even when sufficient machines are available.
Q4. Should machine efficiency be included in production calculations?
Yes. Theoretical calculations assume ideal conditions, but actual production is influenced by efficiency losses, machine breakdowns, operator skill variation, and style complexity. Considering efficiency produces more realistic planning figures.
Q5. How often should sewing production calculations be reviewed?
Production calculations should be reviewed whenever there is a change in style, production volume, manpower availability, machine allocation, or production target. Regular review helps maintain accurate capacity planning.
Conclusion
Sewing production calculations provide the foundation for machine planning, manpower allocation, capacity estimation, and floor space determination in garment manufacturing. When combined with efficiency analysis and proper line balancing, these calculations help factories achieve higher productivity, smoother workflow, and better production control.
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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 to Wikipedia.
