We collected the existing SMV chart from the IE department for the Five Pocket Pant. However to improve the productivity we needed to make some alterations to the existing SMV. We found some gaps in the production process and tried to improve the time utilization of the workers.
The worker rating calculated in the existing SMV calculation was 70% which is very low in today’s competitive market. We calculated the SMV using 80% worker efficiency.
For example, the facing attached with pocketing requires 0.37 minutes in the existing process.
With existing OT and Performance Rating,
Basic time = Observed time x Performance rating = (0.51 x 70)/100 = 0.36 minute
SMV = Basic Time + (Basic Time x Allowance) = 0.36 + (0.36 x 0.05) = 0.37 minute
With new OT and Performance Ratings,
Basic time = Observed time x Performance rating = (0.42 x 80)/100 = 0.333 minute
SMV = Basic Time + (Basic Time x Allowance) = 0.333 + (0.333 x 0.05) = 0.35 minute
Increasing Productivity and Reducing Cost
Here are the things we can try to improve the performance rating of the workers
- Provide regular training to enhance sewing skills and speed.
- Optimize workstation layout to reduce unnecessary movements and fatigue.
- Implement incentives tied to performance and recognize exceptional work.
- Set clear and achievable performance goals for each worker.
- Conduct studies to identify bottlenecks and streamline workflows.
- Foster open communication for workers to provide feedback and suggestions.
- Ensure workers have access to high-quality and well-maintained tools.
- Optimize material flow and implement just-in-time practices.
- Foster a positive work culture that promotes teamwork and collaboration.
- Implement a robust performance tracking system.
- Conduct regular performance reviews to provide feedback and set goals.
- Ensure workers have access to healthcare and support for well-being.
| Work Station | Operation | Machine Type | Existing SMV | Proposed SMV |
| 1 | Facing Attach with Pocketing | Single needle lock stitch machine | 0.37 | 0.35 |
| 2 | Coin pocket attach with front pocket facing | Double needle lock stitch machine | 0.66 | 0.6 |
| 3 | Coin pocket Over lock, S/fly O/L, Front Rise O/L, D/Fly O/L | O/L machine(1N/3T) | 0.6 | 0.55 |
| 4 | Zipper Join with single fly, Single fly edge stitch, Single Fly join with Body | Single Needle Lock Stitch Machine | 0.58 | 0.55 |
| 5 | J stitch make | Double Needle Lock Stitch Machine | 0.25 | 0.25 |
| 6 | D/Fly Join With Body | Single Needle Lock Stitch Machine | 0.21 | 0.21 |
| 7 | Front Rise Join, Zipper Close Stitch | Single Needle Lock Stitch Machine | 0.59 | 0.55 |
| 8 | Front Rise Top Stitch | Double Needle Lock Stitch Machine | 0.31 | 0.31 |
| 9 | Facing Mark & Make | Done by manually | – | – |
| 10 | Front Pocket Mouth Make | Double Needle Lock Stitch Machine | 0.61 | 0.55 |
| 11 | Front Pocket Opening Tack | Double Needle Lock Stitch Machine | 0.61 | 0.56 |
| 12 | Front Pocket Opening Tack | Single Needle Lock Stitch Machine | 0.35 | 0.35 |
| 13 | Front Pocket Bag O/L | Over Lock Machine(1 Needle 3 Thread) | 0.42 | 0.42 |
| 14 | Front Pocket Bag Top Stitch | Single Needle Lock Stitch Machine | 0.48 | 0.48 |
| 15 | Coin Pocket Mouth Rolling, Back Pocket Mouth Rolling | Single Needle Lock Stitch Machine | 0.49 | 0.49 |
| 16 | Coin Pocket Iron | Done by manually | – | – |
| 17 | Back Yoke Top Stitch By Foa Folder | Feed of the arm Machine | 0.34 | 0.34 |
| 18 | Back Rise Top Stitch By Foa Folder | Feed of the arm Machine | 0.35 | 0.35 |
| Work Station | Operation | Machine Type | Existing SMV | Proposed SMV |
| 19 | Back Patch Pocket Join Points Mark | Done by manually | 0.38 | 0.38 |
| 20 | Back Pocket Attach | Single Needle Machine | 0.51 | 0.51 |
| 21 | Back Pocket Attach | Single Needle Lock Stitch Machine | 0.51 | 0.51 |
| 22 | Back Pocket Attach | Single Needle Lock Stitch Machine | 0.51 | 0.51 |
| 23 | Back Pocket 2nd Stitch Mark | Single Needle Lock Stitch Machine | 0.85 | 0.65 |
| 24 | Quality Check | Done by manually | 0.15 | 0.15 |
| 25 | Front and Back part Select and Side Mark | Done by manually | 0.41 | 0.41 |
| 26 | Side Seam Joint by Five | Single Needle Lock Stitch Machine | 0.51 | 0.51 |
| 27 | Side Seam Join By Five Thread O/L | O/L Machine | 0.52 | 0.52 |
| 28 | The feed of the arm Machine | Single Needle Machine | 0.6 | 0.55 |
| 29 | Inseam join By Foa Folder | Buttonhole Machine | 0.43 | 0.43 |
| 30 | Inseam join By Folder | The feed of the arm Machine | 0.54 | 0.5 |
| 31 | Shade label join | Single Needle Machine | 0.27 | 0.25 |
| 32 | The feed of the arm Machine | Buttonhole points mark | 0.41 | 0.41 |
| 33 | Inseam join By Folder | Feed of the arm Machine | 0.54 | 0.54 |
| 34 | Waistband join By Folder | Waist belt setting Machine | 0.55 | 0.55 |
| 36 | Quality Check | Done by manually | 0.15 | 0.15 |
| 37 | Waistband Mouth Close top | Single Needle Lock Stitch Machine | 0.5 | 0.5 |
| 39 | Loop Attach position mark | Done by manually | 0.45 | 0.45 |
| 40 | Loop top and bottom tack | Single Needle Lock Stitch Machine | 0.6 | 0.5 |
| Work Station | Operation | Machine Type | Existing SMV | Proposed SMV |
| 42 | Bottom hem make | Single Needle Lock Stitch Machine | 0.48 | 0.48 |
| 44 | Body bar tack | Bar tack Machine | 0.5 | 0.5 |
| 45 | Loop bar tack | Bar tack Machine | 0.56 | 0.5 |
| 46 | End line Quality Check | Done by manually | 0.15 | 0.15 |
| Total Time | 18.3 | 17.52 |
Calculation –
Labour cost / hour = $0.48
Overhead cost / hour = $0.35
Other cost / hour = $0.20
Total cost / hour = $0.48 + $0.35 + $0.20 = $ 1.03
Now to make 200,000 pieces of garments –
With Current SMV –
Total working hours required = (200,000 x 18.3)/ 60 = 61,000 hrs
Then, Total cost = 61,000 x 1.03 = $62,830
With Proposed SMV –
Total working hours required = (200,000 x 17.52)/ 60 = 58,400 hrs
Then, Total cost = 58,400 x 1.03 = $60,152
Cost saving / month = $62,830 – $60,152 = $2,678
So, with the proposed SMV they can save $2,678 / month
