The Garment Industry Efficiency Calculator measures the productivity of a manufacturing process. It helps factory managers and production planners understand how effectively their resources are being used. By calculating efficiency, a company can identify areas for improvement, set production targets, and track performance over time. Ultimately, this tool provides a clear picture of how much productive work is accomplished compared to the total time workers are present.
formula
To find the efficiency of a production line or factory, you use a primary formula supported by several other calculations. These work together to give you a complete and accurate efficiency percentage.
Efficiency Calculation
This is the main formula to calculate the efficiency of a single operator, a production line, or the entire factory. It measures the ratio of productive time to the total time attended.
Efficiency (%) = (Total Minutes Produced / Total Minutes Attended) * 100
Variables:
Total Minutes Produced: The total standard time earned by producing garments.
Total Minutes Attended: The total time workers spent on the production floor.
Supporting Formulas
You need these formulas to calculate the variables used in the main efficiency formula.
Total Minutes Produced
This represents the total number of garments produced, measured in standard time.
Total Minutes Produced = Total Pieces Produced * Standard Allowed Minute (SAM)
Variables:
Total Pieces Produced: The total number of finished garments.
Standard Allowed Minute (SAM): The standard time established for producing one garment.
Total Minutes Attended
This is the total time all workers were available for work, measured in minutes.
Total Minutes Attended = Number of Workers * Hours Worked per Worker * 60
Variables:
Number of Workers: The total number of operators and helpers in the line or factory.
Hours Worked per Worker: The duration of the work shift in hours.
Core Component Formula: Standard Allowed Minute (SAM)
The accuracy of the efficiency calculation depends heavily on an accurate SAM. SAM is the time a qualified worker should take to complete a specific task at a standard performance level.
Standard Allowed Minute (SAM) = Basic Time + Allowances
Variables:
Basic Time: The time required by a qualified worker to complete a task without any allowances.
Allowances: Additional time given for personal needs, fatigue, and unavoidable delays.
Basic Time Calculation
This normalizes the time taken by an operator to a standard performance level.
Basic Time = Cycle Time * Performance Rating
Variables:
Cycle Time: The average time observed for an operator to complete one full cycle of an operation.
Performance Rating: An assessment of the operator's speed compared to a standard pace.
Allowances
Allowances are typically added as a percentage of the Basic Time. For instance, common allowances include:
Machine and Personal Allowances: Time for personal needs and minor machine adjustments.
Bundle Allowances: Time for handling bundles of cut pieces.
If Basic Time is 0.80 minutes, with a 20% allowance for machine/personal needs and 10% for bundle handling:
Allowances = 0.80 * (20% + 10%) = 0.80 * 0.30 = 0.24 minutes
SAM = 0.80 + 0.24 = 1.04 minutes
Industry Efficiency Benchmarks
This table provides general efficiency benchmarks for different types of garment factories. You can use it to compare your own efficiency levels against industry standards.
| Factory Type | Target Efficiency Range | Description |
| Basic T-Shirt Production | 60% - 70% | High volume, simple operations. |
| Woven Shirts/Blouses | 50% - 60% | More complex operations and handling. |
| Formal Trousers/Pants | 45% - 55% | Requires precise tailoring and more steps. |
| Lingerie/Intimate Apparel | 40% - 50% | Involves delicate fabrics and complex construction. |
| Outerwear/Jackets | 35% - 45% | Very complex, with many components and operations. |
| High-Fashion/Bespoke | 30% - 40% | Low volume, highly detailed, and non-standardized work. |
Example
Let's calculate the efficiency for a production line.
Imagine a production line has the following details:
Number of Workers: 30
Hours Worked per Worker: 8 hours
Total Pieces Produced in one day: 1,200
Standard Allowed Minute (SAM) for the garment: 1.5 minutes
First, you calculate the Total Minutes Attended.
Total Minutes Attended = Number of Workers * Hours Worked per Worker * 60
Total Minutes Attended = 30 * 8 * 60 = 14,400 minutes
Next, you calculate the Total Minutes Produced.
Total Minutes Produced = Total Pieces Produced * SAM
Total Minutes Produced = 1,200 * 1.5 = 1,800 minutes
Finally, you calculate the overall efficiency.
Efficiency (%) = (Total Minutes Produced / Total Minutes Attended) * 100
Efficiency (%) = (1,800 / 14,400) * 100 = 12.5%
This result shows that the production line has an efficiency of 12.5% for that day.
Most Common FAQs
Achieving 100% efficiency is a theoretical goal, but it is not practical in a real factory setting. The efficiency formula accounts for the total time workers are on the floor, including time for unavoidable delays like machine breakdowns, waiting for materials, or team meetings. Since it is impossible to eliminate all non-productive time, efficiency will always be less than 100%. A high efficiency score indicates that non-productive time has been minimized.
Several factors can contribute to low efficiency. Common reasons include frequent machine breakdowns, a lack of proper training for operators, poor workflow management leading to bottlenecks, inconsistent supply of raw materials, and high employee absenteeism. Identifying and addressing these root causes is the first step toward improving overall productivity.
To improve efficiency, a factory can focus on several key areas. First, implement a regular machine maintenance schedule to reduce downtime. Additionally, provide continuous training to workers to enhance their skills and speed. Optimizing the production line layout can also minimize movement and bottlenecks. Finally, ensuring a smooth and steady flow of materials to each workstation prevents operators from waiting idly.