Effectiveness & Efficiency in

Garment Manufacturing Industry.

There was a time when letter was the only way to communicate. Emergency letters were
moving through Express Mail Service. This Express Mail Service was taking nearly double
money than regular mail service & reaching to its recipient within fastest period of time
but now thousands of mails are coming within no second in your computer. Laptop was
the carrying computer for instant communication. It was made handy so that you can
carry & communicate from where ever you want but smartphone completely changed the
concept & the whole world you are carrying in your hand. All these examples given above
are the effective way of communication & increase your efficiency.

From the very beginning of the industrialization and up to now, efficiency is the only
element what has been focused. Industrial Engineering concepts started late 18th century
focusing efficiency, Renowned Toyota Production System had been built to increase
efficiency, Lean & Six Sigma practices started only concentrating efficiency, Software
companies are developing various useful software only keeping a reason behind,
efficiency.

Efficiency is the only element which is creating business, efficiency is the only element for
which businesses are running, efficiency is the only element inventions are made for and
the most important thing efficiency is the only element for which mankind will be jobless
in near future.

Just think for a while how efficiency changed the world & how efficiency is changing the
world from letter to smart phone.

As per Peter Drucker ( A consultant of practical foundations of the modern business corporation)
efficiency is one of the main element for business existence. Jesse Brogan (a senior member
of IIE and three-time president of the Baltimore Chapter) stated in his article “Only 2 Metrics
Matter” one is effectiveness & another one is efficiency. Efficiency is the minimum
condition of survival of a business.

Efficiency is an important dimensional tool for a company to earn profitability. It is such

an important element which gives dimension to improve process & increase productivity
applying less efforts.

If I mathematically define, then efficiency is basically a comparison between two

measurements and those are what has been done against what was required to be done
or what should be done.

Efficiency is always dependent on effectiveness. Efficiency and effectiveness mean two

different things when it is applied to process management. Efficiency of a product
production is only successful when its production & assembly of every process is effective.
Effectiveness is DOING RIGHT THINGS while Efficiency is DOING THE
THINGS RIGHT.

After discussing above all the things my understanding is when you do a right thing to
complete a process, this is basically effectiveness and when you complete couple of
process to complete a job then it is doing the right thing and you become habituated to do
that right thing & your speed of doing that right thing increases & you produce more &
more until a certain level of limit that is basically efficiency.

For example, a garment manufacturing industry producing bottom. They got an order
from GAP which is having a zig zag deco stitch on right knee. Due to improper follow-up
zig zag deco stitch done on left knee instead of right knee. Production was running in full
swing. Buying QC came for production follow-up after 3 days of starting production &
found more than thousand pieces of production done with wrong placement of zig zag
deco stitch.

Workers were efficient enough to produce but production process was not effective and
due to ineffective process control manpower, time, fabric, thread, electricity, rent ect.
everything spoiled. Result of last 3 days is completely ZERO. Despite of having efficiency,
lack of effectiveness made every efforts futile.

For those reasons, value of a person operating in the industrial environment is dependent
on three attributes:

Technical talent,
Ability to understand management concepts,
Ability to communicate to the root level employees

These three qualities are closely involved in the development process so that final
outcome of an individual's effort can be the best representation towards to the product &
to the Effectiveness Formula :

E=C[M(T)]

Where

Mathematically measurement is either 0 or 1.

Notice that M operates on T (technology), and C (Communication ability and skills)

operates on M (Management concept awareness)

Net effectiveness is zero if any of the terms is zero means more than thousand pieces
production (Effectiveness) is zero since Management concept awareness is zero &
Communication ability is zero only Technical ability 1.

Now coming to another matrix efficiency i.e. DOING THINGS RIGHT. Garment
manufacturing industry producing garment having chain process of a specific layout
based on production requirement. For example a stitching line producing 1200 pieces of
5 pocket trouser having layout of 50 machines. Does it mean every machine is producing
110 Pcs per hour ? No it doesn’t mean that. It is actually depending on the requirement
of production process. To complete 1100 Pcs production, some process need 2 machines
to support 120 Pcs production per hour and some cases 1 machine completing 2 process
i.e 120 pieces each process i.e. 240 pcs in an hour. In garment manufacturing industry
productivity is eventually described as efficiency. The more productivity is done by a line
is the more efficient line in the unit. Efficiency calculation done in the garment industry
is not actually efficiency calculation, basically that calculation is productivity
achievement calculation.

Let’s give an example, IE made a production bulletin of a Chino Shorts describing

Process Breakup, Cycle Time, Process Capacity, SMV, SAM and Productivity according
to SAM. Productivity according to SMV is called Target in 100% Efficiency. Productivity
according to the SAM is basically target per day which is coming 65% to 70% of SMV.
But production done 110 Pcs per hour which is eventually 50% achievement.

In this situation 221 Pcs production can be done according to SMV which is in 100%
efficiency.

143 pcs per hour targer set according to SAM which is 65% of SMV means 65%
efficiency cause various allowances have been calculated which is 35%

But 110 pcs production done which means 50% of SMV achieved i.e. 76.92% of SAM and
110 pcs is the best this production line can produce then we can say efficiency of this
production line is 50% against SMV

Kindly give your views regarding this article so that this knowledge can be enriched
more.

Mathematical determination of Efficiency.

Determining efficiency of a worker is an important factor. Garment manufacturing
industries are working in chain process production system where each machine operator
is producing or completing his task which is moving forward to next machine to
complete another task. Every individual machine operation or task is either making or
assembling & finally end of this chain process complete product is coming out. So 2
types of efficiency calculations are done in garment manufacturing industries & those
are individual operator’s efficiency & efficiency of complete chain process which is
basically known as Line Efficiency. Result of efficiency calculation is always given as
percentage.

So first moving to individual operator’s efficiency. Individual operator’s efficiency

means how much time an operators are consuming to complete the task & how much
task he has completed during his working time which means :
Average time consumed to complete a task.
Allowed allowances to complete a task
Quantity of completed task during his working time.

Let’s give an example to make clear of efficiency calculation :

An operator is attaching a patch pocket of a 5 Pocket Trouser. Average time of his

operation is 45 second then what is his efficiency percentage and the calculation is
coming :

(45÷60)+20% = 0.9 Min i.e. 0.9 Min (which is basically SAM.) So to complete an
operation 0.9 Min spent which means he can complete 66 task in an hour & 528 task in
8 hours working period. Here 20% has been calculated as various allowances.

So Efficiency of this operator is :

(Total Task completed x SAM x 100) ÷ ( Working Period x 60)

= (528 x 0.9 x 100) ÷ (8 x 60)
= 47520 ÷ 480
= 99%

For this particular task operator’s efficiency is 99%

Now coming to Line Efficiency & let’s start with giving an example to make it clear.

A stitching line producing 1000 Pcs 5 Pocket Trouser in 8 Hrs Time with 50 Machines
layout. SMV of this style is 18 so the line efficiency is :

(Total output x SAM x 1000) ÷ (No. of Operator x Working time in minute)

= {1000 x (18 +20%) x 100} ÷ {50 x (8 x 60)}
= (1000 x 21.6 x 100) ÷ (50 x 480)
= 2160000 ÷ 24000
= 90%

Here 20% has been calculated as various allowances.

So Line Efficiency is 90%. If line fail to produce less than 1000 Pcs then efficiency will
decrease & if line is producing more than 1000 Pcs then efficiency will increase.

S. S. Munna
Executive Director
Creative Collections Ltd.
Ha-Meem Group
01711 621 703