Standard Minute Value: SMV in Garments, Calculation, Importance

Standard Minute Value: SMV in Garments, Calculation, Importance

The term Standard Minute Value – SMV is mostly used in the garments industry and it is a common measurement calculated by the Industrial Engineer. Generally, SMV indicates the time taken to make garments by the workers using the right types of machinery. In garments factory, you may find that many people used to the SAM – Standard Allowed Minute which is same as SMV. SMV varies garments to garments, style to style, factory to factory. Management and buyers ask for SMV and it is the responsibility of the IE department to calculate SMV and give it to the respective parties. Here in this article, I will share details of Standard Minute Value: SMV in Garments, Calculation, Importance with a practical example.

Industrial Engineering is concerned with the design, improvement, and installation of an integrated system of men, machinery, and materials. SMV is one of the most important tools used by IE.

Standard Minute Value - SMV in Garments, Calculation, Importance

The prime objective of industrial engineering is:

  • To Increase Productivity
  • To eliminate waste and non-value added activities
  • To come up with the optimum use of scarce resources that would bring out the best results.

Importance of SMV in the Apparel Industry

The reason Why we use SMV in Garments Factory is given below

  • SMV is calculated for doing a costing of garments
  • It is used for calculation of target and set the right target
  • For Calculating the Efficiency of workers
  • SMV is calculated for making a plan and take effective factory production decision.

For Calculating SMV – Standard Minute Value in Garments you must have a proper idea of machine operating procedure and working process of workers. Close observation of Industrial Engineer is required to calculate the right SMV for a particular product or style in your factory.

Basically, SMV is the sum of the basic time requirement and allowance applicable to it. Normally allowance is given at the rate of 10% based on the efficiency.

Formulas of Calculating SMV

SMV in Garments Formula

Calculation of SMV in Garments

SMV = (Basic Time + Allocated Allowance)

The formula of Basic Time = Observe Time x Rating Factor

Basic Time: Basic time is the most likely time required to make garments considering observe time and applicable rating factors.

Observe Time: Time taken to do a work when an observer is observing closely and record the worker’s work speed.

Calculation of Observe Time = Total Cycle Time is divided by Number of Cycle

Cycle Time: Cycle Time is the time between starting a garments manufacturing and finishing of those garments.

Rating Factor: Rating factor is assigned based on an evaluation of worker performance which is conducted through eye judgment. A worker can be fast, slow and rating is on a scale of 100% to lower.

Costing SMV is calculated for sending SMV information to buyers. Normally 5% additional time is added with the actual SMV.

Costing SMV = Actual SMV + (Actual SMV x 5%)

Example of Calculation of SMV in Garments

Suppose for making a product the following assumption is there

  • Observe Time = 25 Minutes
  • Rating of Operator = 80%
  • Considering Allowance = 10%
  • Basic Time = 25minutes x 80% = 20 minutes
  • Allowance = 20 x 10% = 2 Minute

So, SMV = 20 minutes + 2 minutes = 22 minutes for making a particular garments product

Calculation of Capacity of Single Operator in Garments

  • If an operator works for 10 Hours a day
  • 30 minutes to make a product

Capacity = (1 operator x 10 hours x 60 minutes)/30 Minutes = 20 Pieces of Garments by an operator

If you assign 100 operators then your capacity will be = 100 operators x 20 pieces = 2000 pieces a day

Calculation of Efficiency Percent

  • SMV 22 Minutes
  • Working Hours 10 a Day
  • Number of Operators 100 person
  • Actual Production 2000 pieces

Efficiency (%) = (2000 pieces x 22 minute)/(100 operators x 10 hours x 60 minutes) x 100 = 73.33%

whereas the target was,

Target = (10 hours x 60 minutes x 100 operators)/smv 22 minutes = 2727 Pieces of garments

SMV of Different Types of Garments Manufacturing

Hopefully, you understand what is Standard Minute Value: SMV in Garments, Calculation, Importance of SMV in the apparel industry. If you have any confusion then please let me know. I will try to clarify farther in details.

Written by

Md. Nahian Mahmud Shaikat

Operation Breakdown, SMV and Layout of Blouse Manufacturing

Operation Breakdown, SMV and Layout of Blouse Manufacturing

A blouse is worn by the women in South Asian, it is worn in the upper part of a body. As per this sewing operation bulletin, total SMV is 4.73 and 25 sewing machine will be needed. Here also available downloadable excel sheet for your clarification. Hopefully, after reading this you will have a good idea of Operation Breakdown, SMV and Layout of Blouse Manufacturing.

Operation Breakdown, SMV and Layout of Blouse Manufacturing
NO OPERATION M/C Type Attach. M/C TGT MAN LAY
Foots S.M.V LVL OUT
FRONT PART
1 Front Two part O/L 3T O/L 0.1 600 0.53 1
2 Front two-part joint S/N 0.15 400 0.79 0.5
3 Btn placket making mark & Make S/N 0.25 240 1.32 1
4 Ticken Mark at back part Helper 0.15 400 0.79 1
5 Ticken tack at back part S/N 0.16 375 0.85 1
6 Solder joint 5T O/L 0.15 400 0.79 1
7 Slv rolling S/N 0.25 240 1.32 1
8 Slv joint 5T O/L 0.3 200 1.59 2
9 Side joint 5T O/L 0.2 300 1.06 1
10 Hanger loop, Btn loop measure & Cut Helper 0.22 273 1.16 1
11 Hanger loop tack S/N 0.15 400 0.79 1
12 Btn loop Make & joint S/N 0.2 300 1.06 1
13 Neck tape joint with body S/N 0.45 133 2.38 2
14 Neck top stt. S/N 0.35 171 1.85 2
15 Front Hem tape joint with body S/N 0.5 120 2.64 3
16 Back Hem tape joint with body S/N 0.3 200 1.59 2
17 Back Hem tape Top stt. S/N 0.2 300 1.06 1
18 Front Hem tape Top stt. S/N 0.45 133 2.38 2
19 Tack at underarm S/N 0.1 600 0.53 0.5
20 Main lbl joint S/N 0.1 600 0.53 0.5
TOTAL     4.73 0.19 25 25
  GRAND TOTAL     4.73 0.19 25 25

Summary of Sewing Operation Bulletin of  Blouse Manufacturing

Man & M/C REQUIREMENT
NO MACHINE TYPE REQ
1 S/N 18
2 D/N
3 O/L
4 3T O/L 1
5 4T O/L
6 5T O/L 4
7 2T F/L (Chain)
8 Button Attach
9  F/L
10 F/O/A
11 Ironman
12 Helper 2
13 Chain stc
14 O/L (Chain)
15 Buttonhole
16 KANSAI
TOTAL 25

Here,

  • S/N Single needle lock stitch
  • D/N Double needle lock stitch
  • O/L Overlock machine
  • 3T O/L 3 Thread overlock machine
  • 4T O/L 4 Thread overlock machine
  • 5T O/L 5Thread overlock machine
  • F/L Flat Lock machine
  • F/O/A Feed of the arm

Operation Breakdown, SMV and Layout of Blouse Manufacturing

Blouse Operation Bulletin (excel)

Written by

A.M. Amirul Islam (Washim)
Email: [email protected]

Linkedin: A.M. Amirul Islam

Visual Management System in Apparel Industry

Visual Management System in Apparel Industry

Visual management is a part of lean manufacturing; an effective and standard method to communicate with every level of a factory with necessary information, a concept is to understand everything when a person visits manufacturing floor by visual data display system also include an important message for employees for learning, doing and achieve. Visualization boards applied in a factory for delivering information such as production status, production trend, Quality controlling status, delivery performance, and customer report. Visual controls are means, devices, or mechanisms that were designed to manage or control our operations (processes) so as to meet the purposes: informative, identification, instructional and planning. Here in this article, you will have an idea of what we can visualize, tools used, and advantages of Visual Management System in Apparel Industry.

Visual Management System in Apparel Industry

What are Generally Visualize in Garments Factory

  1. Hourly production board
  2. Efficiency graph, individual and line wise
  3. Quality DHU%, RFT
  4. Production and Quality target, Target vs Actual
  5. A counter sample for the sewing line
  6. Production Downtime & Performance Dashboard
  7. Delivery performance report
  8. All KPI reports
  9. Responsibilities of sewing operator
  10. Pareto analysis
  11. Kanban board
  12. Best sewing line names, best supervisors and operator
  13. Section wise safety assessment list and picture

Digital Visual Board in Garments Production Floor

 

List of Tools can be Used to Visualize Garments Factory

  1. Visual control boards
  2. Digital computerized board
  3. Visual workstation
  4. Signs, labels, name tags and direction
  5. Borders, lines; level scales
  6. Board, Shadow board, shadows, color codes and displays (i.e. Colour and shape)
  7. Graphs, info graph charts,
  8. Photos, films,
  9. Posters
  10. Mascots,
  11. Sketches
  12. Drawings
  13. Models
  14. Sticky
  15. Decision
  16. Trees,
  17. Kanban systems (cards, lights)

Advantages/ Benefits of Visualization in the Apparel Industry

  1. Increase effective communication and easy understanding for all
  2. For successful outcomes from the production floor
  3. Immediate assessment of the daily and weekly goals
  4. To motivate employees
  5. To familiarize or set the stage for a performance/event
  6. Absorb information quickly.
  7. Understand the next steps
  8. Share the insights with everyone
  9. It’s easy to understand and clarify
  10. Proper and regular updates
  11. Immediate Performance Information
  12. Evidence of actual achievement

This article also refers to

  • Visualize Garments factory
  • How to visualize Garments manufacturing key tools

Visual Management in the Apparel industry pdf

Written by

A.M. Amirul Islam (Washim)
Email: [email protected]

Linkedin: A.M. Amirul Islam

What is WIP, WIP Calculation, Reducing, Reporting in Garments Manufacturing

What is WIP, WIP Calculation, Reducing, Reporting in Garments Manufacturing

What is WIP? What does WIP mean in Apparel Industry? WIP means Work In-progress or In-process, an inventory system in the Garments manufacturing process in cutting, sewing and finishing but not for raw materials warehouse or finished goods warehouse. WIP for the manufacturing floor the quantity between input and output what backlogged in production. In this article we will see the details of What is WIP, WIP Calculation, Reducing, Reporting in Garments Manufacturing.

What is WIP, WIP Calculation, Reducing, Reporting in Garments Manufacturing

WIP Calculation of Cutting, sewing, Washing, and Finishing

  • Cutting WIP = Total cut quantity – Total quantity inputted to the sewing section

For example, Cutting section cut total 10,000 pieces for style# 5572819 and 7520 pieces have been inputted to the sewing department, then cutting room WIP will be =(10,000-7520) =2480 pieces.

  • Sewing Line WIP = Total pieces (GMTS Qty) inputted to the line – Total number of garments sewing output completed

For example, if a sewing Line totals 7520 pieces have been got input for style#5572819 and a total of 3500 pieces are produced from the line. Sewing line WIP is (7520-3500) = 4020 pieces.

Limiting washing WIP is very much important because most factories don’t have own washing facility. So they have to send Garments to another factory for washing. Delaying in washing can effect on time delivery.

  • Washing WIP= Total Garments sent to washing – Total Garments received from washing

Finishing, the last stage of Garments manufacturing, garments manufacturer challenge limiting washing and finishing WIP. Every factory especially follows up washing and finishing WIP to maintain on-time delivery to the customer.

  • Finishing sections WIP = Total Garments received from washing – Total packed quantity

WIP Report Format for the Apparel Industry

It is very easy reporting WIP, doesn’t need to make a format for checking WIP, you can keep WIP calculation in a production report. Here excel reporting format uploaded to download for all of you.

Cutting and Sewing WIP

Daily Production Report – Sewing
Line Name Style Order Quantity Al. Quantity Input Date Day Input Ttl Input Day Output Total Output Input Balance Output Balance Line WIP
A 808-8126 18211 19571 28-May-18 15401 1440 15300 4170 4271 101
A & B 808-8129 11897 12851 31-May-18 579 12413 1552 12407 438 444 6
B 834-4100 3000 3242 7-Jun-18 1263 3122 1208 2140 120 1102 982
C 808-2844 6570 6936 30-May-18 6714 925 6095 222 841 619
E 899-4241 30912 21278 22-May-18 2108 21278 1300 18330          – 2948 2,948
F 899-4241 30912 10444 4-Jun-18 2108 10444 1600 9590          – 854 854
G 808-8514 3060 3444 9-Jun-18 1099 305 305          –          – 794
H RM1005109 3202 3425 9-Jun-18 889 1996 600 600 1429 2825 1,396
I RM1020409 4115 4445 6-Jun-18 4384 1205 3540 61 905 844
J RM1020509 5854 6243 4-Jun-18 6174 1500 5961          –          – 213

Washing and Finishing WIP Report

Total Sent to Wash Day Receive from Wash Total Receive from Wash Work in Process in Wash
25401 7 25192 209
17234 61 17112 122
10082 54 10057 25
13065 33 13050 15
16154 44 16150 4
2173 82 2137 36
Total Wash Receive Day Poly Total Poly Poly Balance/Finishing WIP
79274 1200 3500 75774
19545 320 1850 17695
531 55 111 420
104 100 100 4
4664 1800 3855 809

Download WIP report format in excel chart

How to Limit excessive Work In-process (WIP) in Garments production Floor

  1. Reducing bottleneck and productivity improvement
  2. Adding machines and improving workforce
  3. Proper Layout and machine allocation
  4. Follow Kanban board in the production floor
  5. Keeping accurate production flow chart/ sequence
  6. Producing a good quality product and stopping re-work

Problems of Excessive WIP for Apparel Industry

  1. Transit areas become obstructed and blocked
  2. Garments gathering in the workplace
  3. Garments inadequate to maintain a good appearance
  4. Hamper normal production flow
  5. Poor housekeeping

This Content also has an answer of below points

  • How to find out WIP in the Apparel industry
  • Limiting WIP in the Apparel industry
  • WIP follow up in the Apparel industry
  • WIP calculation of Cutting
  • WIP calculation of Sewing
  • WIP calculation of Washing
  • WIP calculation of Finishing

Written by

A.M. Amirul Islam (Washim)
Email: [email protected]

Linkedin: A.M. Amirul Islam

Kanban Board in Garments Manufacturing Production Floor

Kanban Board in Garments Manufacturing Production Floor

What is Kanban? Kanban is a visual card or billboard; Japanese word which meaning Cards or board, a tool of lean manufacturing for visualization entire production teamwork to control production focusing on creating a production system more effective and efficient, focusing mainly in the production and logistics activities. Kanban is a visual system as ‘Signal card’ indicate what to do, items will put when needed, Kanban cards order necessary task, update with time and surely reduce wastage. In this article, you will have an idea of how kanban board in garments manufacturing production floor is used.

Kanban Board in Garments Manufacturing Production Floor

Types of Kanban System

Generally, two types of Kanbans or Kanban Cards used in the apparel industry:

Production Kanban

Production Kanban is the first step of Kanban implementation, production Kanban takes the place of standard production orders in material requirements planning (MRP) push.

Transportation Kanban

Transportation Kanban system is very important that carried on the trolley, containers that are associated with the transportation to move through the loop again.

Importance of Implementation Kanban Board in Apparel Industry

  1. Reduce idle time in a production process.
  2. Increase productivity, more effective and efficient production
  3. Visualize work and optimize the flow of the work
  4. Reduce WIP (Work in Process)
  5. Improve workflow
  6. Avoidance of over-production and limitation of stocks
  7. Higher availability of materials
  8. Reduce inventories
  9. Improve communication between management and operational staff

Garments Kanban Board Information Includes

  1. Backlog
  2. To do list
  3. Doing List/ work-in-process List
  4. Work completed List
  5. Plan list
  6. Lot name
  7. Process name

This content also have the answer of below points

  • Kanban system in Apparel manufacturing
  • Set up Kanban board in the production floor
  • Kanban board in sewing floor

If you have any confusion then please let me know.

Written by

A.M. Amirul Islam (Washim)
Email: [email protected]

Linkedin: A.M. Amirul Islam