accurate time study

7/31/2019 Accurate Time Study

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Accurate Time Study:The Beginning of Basics

December 13-14, 2002


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What apparel companies need?

Apparel companies need standard cost solution

China signed WTO agreement, more competitiveenvironment is coming ERP (Enterprise Resource Planning) system is building on

foundation of BOM (Bill of Material) and BOL (Bill of Labor) BOM noted the standard costing for material, while BOL list

the standard cost for manufacturing operation. Apparel companies looking for a better method of scheduling Apparel companies looking for a standard that is universal

applicable Expecting the data could be use for production line

balancing. Expecting the data could be used by sales/merchandising

precise costing


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Methods available

Traditional apparel companies heavily dependson experience staff in estimating product cost

Time Base Standard Time base standard are widely used in western

countries from the 30s until now. All operations and labor cost are based on time

unit; the common one are SAH (Standard Allow Hour), SAM (Standard Allow Minute) and SAS (Standard Allow Second)

All time base standard includes allowance forpersonal need, additional incentive andcontingency.


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Rating


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Operation allowance for different machines

Allowance Standards for Various Garment Operations

Machine Machine Personal Incentive

Type Delay & Fatigue

Single Needle -Bobbin . %111 . %11 . %111

-Looper . %11 . %11 . %111

-Top Thread Only . %11 . %11 . %111

Two Needles -Bobbin . %111 . %11 . %111

-Looper . %11 . %11 . %111

-Top Thread Only . %111 . %11 . %111

Three Needles -Looper . %111 . %11 . %111

-Top Thread Only . %111 . %11 . %111

Four Needles -Looper . %111 . %11 . %111

-Top Thread Only . %111

. %11

. %111

Overlocking -Three Thread . %11 . %11 . %111

-Five Thread . %111 . %11 . %111

On the above operations allow a tolerance of +/- . % depending on type of work and length of machine cycle in rela11

(Discuss with supervisor, when in doubt.)

Buttonhole -Bobbin (Single) . %11 . %11 . %111

-Bobbin (Tandem) . %111 . %11 . %111

-Top Thread Only . %11 . %11 . %111

-Chain Stitch (Single) . %11 . %11 . %111

-Chain Stitch (Double) . %11 . %11 . %111

On the following operations, allow % downward tolerance for machine delay on REECE S- tackers.1 1Button Sewing -Bobbin . %11 . %11 . %111

-Top Thread Only . %11 . %11 . %111

Semi-automatic Manual Operations

Creasing (REECE; BRADDING) . %11 . %11 . %111

Bartack -Single . %11 . %11 . %111


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Operation Code

ASS ASSEMBLE LPL LAPEL

ATT ATTACH M/C MACHINE

B&F BEARER & FACING MAN MANUAL

BAG POCKET BAG MRK MARK

BCK BACK NTH NOTCH

BDL BUNDLE OLG OVERLOCK

BEL BELT OPS OFF PRESS

BLL BELT LOOP OSM OUT SEAM

BND BAND PAD PADDING

BPK BACK POCKET PBK PANEL BACK

BRD BRAIDING PCH PATCH POCKET

BSM BACK RISE SEAM PFC PANT FRONT

BTH BUTTONHOLE PIP PIPING

BTS BUTTON SEWING PKT POCKET

CLR COLLAR PLQ PLACKET

CLS CLOSE PLT PLEAT

CTH CATCH PRS PRESS

CUF CUFF QLT QUILTING

DRT DART R&T RUN STITCH & TURN

DSG DRAW STRING RTT RUN, TURN & TOPSTITCHING

ELC ELASTIC RUN RUN STITCHING

F&B FRONT & BACK SET SETF&C FLY & CATCH SEW SEWING

FAC FACING SHR SHOULDER

FAL FALL SLM SLEEVE HEM

FEL FELL SLT SLIT

FIX FIX SLV SLEEVE


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Time Base Standard

Apparel companies has two major method in

establishing Time Base Standard Time Studies which base on industrial

engineering technique by using stop-watch,element breakdown, rating, statistic analysis in

establish SAM data. MTM (Motion Time Measurement) a

technique allow engineer systematicallybreakdown operator motion in a sequence of

motion. By well define the operation motionelements and convert motion code into time.Those time value put together become thestandard value for analysis SAM.


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Limitation on Time Studies

Standard procedures for time studies a. Observe job and analyze to determine element. b. Grade the elements to give assessment of rate of working

compared to accept. c. Use stopwatch to obtain times of each element - raw time. d. Select or average to give accepted time. e. Multiply raw time by grading factor to get 100% time. f. Multiply 100% time by the number of times it occurs per 100

garments to get 100% time / 100. g. Add allowances to 100% time to give standard allowed time. h. These comprise: (1) Machine Delay Allowance (Where applicable). (2) Personal And Fatigue Allowances. (3) Incentive Allowances (Where applicable).


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Limitation on Time Studies

Observe job and analyze to determine

elements is subject to the decision of industrialengineer. It may vary from engineer toengineer. The method adopted by operator areoften different.

Grading is an art. See the example It takes a long time to collect and build up

sufficient samples before standardization couldbe achieved.

SAM can never available before operations areperformed, this is another chicken and eggstory.


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MTM method

International adopted standard from MTM

organization. MTM data is well established and proven

MTM method based on motion analysis, eachmotion is well analysis, excessive andunnecessary motions are removed.

No human judgment on rating.

MTM result could be reused, the motion

sequence allow very detail describe the motionrequired for the job.

Labor union agree on MTM standards.


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Why apparel companies need time base standard?

Example on production capacity calculation

A manufacturing facility has 820 sewing worker

22 working day in a month

8 Hours in a day

60 minute in an hour Capacity input:

820 X 22 X 8 X 60 = 8,659,200 minute

Or 144,320 hour

If basic garment with 18.8 SAM is defined, the factorytheoretical should be able produced 460,595garment in a months time

8,659,200 minute / 18.8 SAM = 460,595 piece


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If above example is extended to a morecomplicated style, the feasible output from thesame manufacturing would vary as following(assume the skill and machine is constant) 8,659,200 minute / 18.8 SAM = 460,595 piece 8,659,200 minute / 20.8 SAM = 416,308 piece

8,659,200 minute / 22.8 SAM = 379,789 piece 8,659,200 minute / 24.8 SAM = 349,161 piece 8,659,200 minute / 26.8 SAM = 323,104 piece

This example show if the style is changing andvary with features and operation intensive, itcould greatly affect the product capacity andcost!


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What about costing?

Let see the costing from other prospective Administrative cost: 250,000 per months Machine depreciation: 228,300 per months Rent and Utilities: 120,000 per month Total overhead could be :

250,000 + 228,300 + 120,000 = 598,300

Cost per input minutes would be $598,300/ 8,659,200 minutes= $ 0.069 per minutes

The overhead absorb would be: Garment with 18.8 SAM = $0.069 X 18.8SAM = 1.2972 Garment with 20.8 SAM = $0.069 X 20.8SAM = 1.4352 Garment with 22.8 SAM = $0.069 X 22.8SAM = 1.5732 Garment with 24.8 SAM = $0.069 X 24.8SAM = 1.7112 Garment with 26.8 SAM = $0.069 X 26.8SAM = 1.8492


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Labor Cost

Direct wage or labor could be calculated as following

Minute wage:

Target wage per month = 800Working days in a month = 22

Minute in a day (8 X 60) = 480

Minute wage = 800 / (22 X 480) = 0.076 per minute

Garment with 18.8 SAM = $0.076 X 18.8SAM = 1.4288 Garment with 20.8 SAM = $0.076 X 20.8SAM = 1.5808 Garment with 22.8 SAM = $0.076 X 22.8SAM = 1.7328 Garment with 24.8 SAM = $0.076 X 24.8SAM = 1.8848

Garment with 26.8 SAM = $0.076 X 26.8SAM = 2.0368


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What happened to total cost?

Lets put overhead absorption and labor costtogether.

SAM Labor Overhead GMT Cost

18.8 0.069 0.076 2.726

20.8 0.069 0.076 3.01622.8 0.069 0.076 3.306

24.8 0.069 0.076 3.596

26.8 0.069 0.076 3.886


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Line balancing

Line BalOPERATION PCS Existing EFFECTIVE Target

DESCRIPTION SAM/111 Per 111 Piece Rate BASE RATE PCS111

-------------------------------- ------- --------- ------- ---------

1SN SEW LABEL & SIZE ON W/B .44444 .44444 .111 .44444 .11

1DN ATTACH WAISTBAND ( )1 .11111 .1111 .111 .11111 .11

1OVLK FLY FACING ( T)1 .11111 .11111 .111 .11111 .11

11OVLK BACK POCKET BAG ( T)1 .11111 .11111 .111 .11111 .11

11WELT POCKET ( )1 .11111 .11111 .111 .11111 .11

11OVLK BEND SIDE OF F.PKT ( T) ( )1 1 .11111 .11111 .111 .11111 .11

11ATT FACING W/TOPSTITCH END .11111 .1111 .111 .11111 .11

11TRIM POCKET BAGS (L & S) .11111 .1111 .111 .11111 .11

11TURN EDGESTITCH & SEW MIDDLE-SIDE .11111 .1111 .111 .11111 .11

11OVLK FRONT JET PKT ( )1 .11111 .11111 .111 .11111 .11

11MAKE DARTS .11111 .1111 .111 .11111 .11

11TOPSTITCH BACK WELT PKT ( )1 .111111 .1111 .111 .11111 .11

11CLOSE BACK PKT BAG ( )1 .11111 .1111 .111 .1111 .11

11TOPSTITCH F.JET PKT ( )1 .111111 .1111 .111 .11111 .11

11ATTACH FRONT PKT BAG & MAKE NOTCH .11111 .1111 .111 .11111 .11

11TOPSTITCH FRONT PKT MONTH ( / )11 .11111 .1111 .111 .11111 .11

11SN EDGESTITC H F.PKT (L PKT BAGS) .111111 .1111 .111 .11111 .11

11OVLK FRONT CROTCH ( T)1 .11111 .11111 .111 .11111 .11

11SET ZIP WITH FLY & CLOSE CROTCH .111111 .1111 .111 .11111 .11

11ATTACH BELT LOOP ( ) & SZ LBL1 .11111 .1111 .111 .11111 .11


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MTM Solution

To enable apparel companies benefit

from Time Base Standard without thelengthen process in collect operationsamples and following procedures on

statistical analysis in establishing SAM. Computer package on MTM creation

could be a quick win for apparel

companies Such as IMPACT software package

from Gerber Technology.


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Gerber IMPACT is a high level MTM-2

base system with easy to use andunderstanding elements.

IMPACT has four major MTM-2 high levelelements DI elements for Dispose HA elements for Handling PO elements of Position PU elements of Pick Up


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IMPACT elements Pick Up

*****************************************

PU11PICK UP PIECE WITH TURN

Left (or right) hand (or both hands) is idle on the table or comingback from disposing the previous piece. The hand(s) moves to reachthe piece and grasps with several finger movements (difficult grasp).Lifts the part up in order to make a turn, brings the piece down tomachine and turns it simultaneously. The right (or the left) handusually also grasps the piece to hold it. The element does not includeany straightening nor any positioning of the piece but does includereleasing of the piece which may take place later on after severalelements.

Left hand #Code Tmu Code #Right hand

1- cm11 11 . min4444

get piecelift to turnturn & bring totable

GC11

PA11

(PA )11

11

1

1

GB1

grasp if needed

11- cm11 11 . min1111

GC11

PA11

PA11

11

1

11

(GB )11

11- cm11 11 . min4444

GC11PA11

PA11

1111

11

(GB )11

11- cm11 11 . min1111

GC11

PA11

PA11

11

11

11

(GB )11

Dispose


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IMPACT element - Position

*****************************************PO11

POSITION UNDER FOOT ACCURATELY

The piece (or pieces) is in hand. The hand brings the piece underthe foot and positions it accurately. The presser foot has been lifted

before the element and will be let down during the next element.

Left hand # Code Tmu Code # Right hand

1- cm11 11 . min1111

put & positionaccurately

PC11

11

= =

11- cm11 11 . min4444

PC11

11 =

11- cm11 11 . min1111

PC11

11 =


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IMPACT element - Handling

*****************************************

HA11ALIGN NOTCHESHands move simultaneously to edges of pieces and align notches.

Control of the pieces shifts to the right hand with finger movements.

The left hand supports the alignment.


1- cm11 11 . min1111Get and align

Support

GB11

PA11

11

1

1

=

R Change control

11- cm11 11 . min1111 GB11

PA11

11

1

11

=R

11- cm11 44 . min1111 GC11

PA11

11

1

11

=

R


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IMPACT element - Dispose

*****************************************DI11

DISPOSE WITHOUT GRASP

The piece is already under control of the hands. Move the piece

aside with one continuous movement.


1- cm11 11 . min1111

move PB11

11

11- cm11 11 . min1111

PB11

11

11- cm11 11 . min1111

PB11

11

11- cm11 11 . min1111

PB11

11


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Category 1


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Category 2


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Class Code


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Components


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IMPACT Element Data Table


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Federal Stitch Type Data Table


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Machine Data Table


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Method Auto Numbers


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Pay Code


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Season Data table


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Skill Code Data Table


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Method Analysis - Header


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Method Analysis Core


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Method Analysis - Result


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Method Analysis Details

S b A bl A t f t


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Sub Assembly A component of a garment

S b A bl A l i


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Sub Assembly Analysis

S b A bl A l i Additi l I f ti


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Sub-Assembly Analysis Additional Information

IMPACT St l


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IMPACT Style

St l A l i


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Style - Analysis

St l Additi l I f ti


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Style Additional Information

W U


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Warp Up

Apparel Companies need Time Base

Standard to enhance existing operationin scheduling, precise costing, costabsorption calculation, line balancing.

Heading with WTO; a more demandingsituation; productivity is the key word.

Need a quick solution, MTM-2 high level

data could be a candidate for you!


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Question?

accurate time study

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