Definition: SMV means standard minute value. Time taken by a standard operator to complete any given operation with pre-determine conditions.
· Industrial Engineering is a branch of
engineering dealing with the optimization at complex processes or systems. It
is especially concerned with the optimization of man, machine, materials, equipment’s
and how to utilize these resources in better method and in proper way to
enhance productivity and quality of work.
An IE is responsible to design a way to produce a product in a quicker, easier and in better method.
Method study: Method study is the systematic recording & critical analysis of ways of doing a job so as to make improvements it analyzes how a work is being done currently to find out ways to improve so that productivity increases. Method study discovers suitable and easier method of work so that the task can be completed quickly.
7 Steps of Method Study:-
1.
Select: Select the job to be study.
2.
Record: Record the all of relevant fact by
direct observation.
3.
Examine: Examine the data/facts critically and
in sequence.
4.
Develop: Develop the most practical, ergonomic
& economic method.
5.
Define: Define the new method in detail.
6.
Install: Install the method as standard and
train the operator to use it.
7.
Maintain: Maintain the new method by regular
routine check.
Definition: A Systematic examination and development of operational method and standards to enhance productivity and quality of work.
Classification of Work Study:
(i) Work Measurement
(i) Method Study
1.
In garment Industry, “Production capacity” is one of the most important play role used for vendor source by the buyers. Buyer can easily understand the order capacity of the vendor. And, they allocate order proportionally to the vendor. So it is very important that marketing and planning personnel should aware about the production capacity of their production units. After read this article anyone can easily understand how to calculate the production capacity of a factory?
According to production planner express the capacity of a
factory in terms of how many machines they have. And also calculate the
production of a particular style produce in a day. Capacity of a factory is
primarily expressed in terms of total machines factory have According to the
style category, machine requirement can be change and daily average production
output can also change.
A factory’s capacity is express in the terms of total
minutes or hours or production per day.
Generally, need to know total machines of a factory &
production runs of a day.
Let,
Total Number of machines=300
Production run of a day=10 hours
So, total factory capacity (in hours) = 300*10 hours =
3000 hours
According to industrial Engineer calculate SAM of a
particular style.
Let,
The SAM of a particular style is 30 minutes.
According to Industrial Engineering department can
understand the historical data or calculate average line
efficiency.
Let,
The style average line efficiency is 70%.
Calculation of production capacity of a factory (Pcs):
Now, we can use following formula to calculate production
capacity.
Production capacity (pcs) = {(Capacity in
hours*60/product SAM)}*line efficiency
Example: Let, a factory has
10 sewing lines and each line has 30 machines. Factory Production runs 10 hours
per day. If factory is producing only one style (Shirt) of SAM 30 minutes and
used daily production capacity at 70%.What is the production capacity of that
factory?
Total machine=10 linesX30 Machines=300 Machines
Total Hour=300 Machines X 10 hours=3000 hours
Total Minutes=3000 hoursX60 Minutes=180000 Min. (1
hour=60 Minutes)
SAM=30 Minutes
Average line efficiency=70%
Production capacity (pcs) = {(Capacity in
hours*60/product SAM)}*line efficiency
= (3000*60/30
= 180000/30 min.
= 6000*0.70(Line efficiency)
=4200 pcs
So, Production Capacity of a day =4200 Pcs(shirt)
Please note that Production will vary according to the
line efficiency and initial days production line efficiency is lower & it
will faster when start full flow of production.
Most important formula for Textile Industrial Engineering
Industrial Engineers are the heart of production based industry at present time. An industry grows up for the hard-working dedicated engineers who do everything for the industry. Because he is the mastermind person for the industry and planned how to do better and better from today to tomorrow.
1. Standard minute value
SMV = Basic time + (Basic time × Allowance)
SMV (Standard Minute Value) =
Basic Time
= (Cycle Time
2. Basic time
Basic time = Observed time × Rating
3. Observed time
Observed time = Total Cycle time / No. of cycle
4. Cycle Time
Cycle Time = 60 / Target
5. Rating
Rating = (Observed Rating × Standard rating) / Standard rating
6. Available
Available minute = Work hour × Manpower
7. Capacity
Capacity = 60 / Capacity time in minute
8. Capacity Achievable
Capacity Achievable = Capacity × Balance
9. Factory capacity
Factory capacity = (Work hour / SMV) × Total worker × Working day × Efficiency
10. Target setup for a line
Target = {(Total manpower per line × Total working min per day )/ S.A.M.} × 100
11. Required no. of the operator
Required no of operator = Target daily output / Daily output per operator
12. Daily output
Daily output = Work hour / SMV
13. Efficiency
Efficiency = (Earn minute × Available minute) × 100
14. Earn minute
Earn minute = No of Pc’s (Production) × Garments SMV
15. General sweing data
GSD = (Man
power × Work hour) / Target
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Description: This tool provides guidelines for using the Plan-Do-Check-Act approach and the steps to engage in the process. How it can be us...
