Operation Breakdown of a Basic T-shirt with SMV and Production Target

Introduction: Operation breakdown of a basic T-shirt means to find out different parts and elements of a basic t-shirt for sewing one after another. Industrial engineers do this job and planning the production process or working flowchart to manufacture a basic t-shirt. Basic t-shirt produces from knit fabric. It's GSM range 130-180. A basic t-shirt is more comfortable and flexible than a Polo t-shirt.

Different Parts of a Basic T-shirt

Common parts of a basic T-shirt: If we breakdown a basic T-shirt, we will find some common parts;

1.   Neck rib  
2.   Front part
3.   Back Part
4.   Left sleeve
5.   Right sleeve
6.   Left sleeve hem 
7.   Right sleeve hem 
8.   Bottom Hem

Operation Breakdown of a basic t-shirt with total cycle time: Operation Breakdown of a basic T-shirt is done by the following table;

SL. No.	Name of Operation	Each Operation Cycle Time	Calculated Production at 100% Efficiency
1	Care Label Attach With Back Part	0.20	300
2	Front & Back Part Match	0.18	333
3	Shoulder Joining	0.33	181
4	Neck Rib Measure & Cut	0.25	240
5	Neck Rib Tack With Body	0.26	230
6	Neck Rib Joining	0.30	200
7	Neck Top Stitch	0.25	240
8	Main Label Attach	0.33	181
9	Sleeve Hem	0.30	200
10	Sleeve & Body Match	0.22	272
11	Sleeve Joining	0.42	142
12	Arm Hole Top Stitch	0.30	200
13	Side Seam	0.57	105
14	Sleeve Close & Open Tack	0.37	162
15	Body Hem	0.46	130
16	Final Thread Cut	0.34	176
	Total Cycle Time	5.08

Table - 1: Operation Breakdown of a Basic T-shirt

From the above table, we get operation breakdown and total cycle time. We also estimate each operation production target which helps us line balancing and preparing machine layout.

You may like: Operation Bulletin of a Basic T-shirt with Machine Layout Plan.

SMV calculation of a Basic T-shirt: 

Problem: From the above table, we find total cycle time is 5.08, suppose the performance rating of all operator is 80% for a basic T-shirt. Now, Find out the SMV for that Basic T-shirt. 

Solution: 

We know,

SMV = Basic time + Allowance

          = ( Cycle time × Rating) + (Bundle allowances + machine and personal allowances)

          = (5.08 × 0.80) + (Bundle allowances + machine and personal allowances)

          = 4.06 + ( 5.08 × 10%)+ (5.08 × 20%)

          = 4.01 + 0.508 + 1.016

          = 5.58

So, we find out SMV for that Basic T-shirt is 5.58 minute.

Production target calculation of a basic T-shirt:

Problem: We find SMV for that basic t-shirt is 5.58. Suppose, No. of worker of that line is 22, the efficiency of that line 85%.  Find out the production target per day of that basic t-shirt in one sewing line.

Solution: 

Here,

SMV = 5.58 Minute.

No. of worker = 22.

Line efficiency = 85% = 0.85

We know, Total working hour in a day = 8 hr.

Now, 

Production Target = {(Total manpower per line × Total working min per day )/ S.M.V.} × Efficiency

                                  = { (22 × 8 × 60) / 5.58 } × 0.85

                                  = 1608.60 ~ 1609

                                  = 1609 pieces.

So, Daily production target = 1609 pieces in one sewing line

and Hourly production target = 1609 / 8

                                                       = 201.13~ 201 pieces / hr.
                                                       = 201 Pieces/hr in one sewing line.

So, From this post, we learn about Operation breakdown of a Basic T-shirt, Total Cycle Time, SMV calculation, and Production target in daily and hourly.

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