Operation Breakdown of a Polo T-shirt with SMV And Production Target

Introduction: Operation breakdown of a Polo T-shirt means to find out different parts and elements of a Polo t-shirt for sewing one after another. Industrial engineers do this job and planning the production process or working flowchart to manufacture a Polo t-shirt. Polo t-shirt produces from knit fabric. It's GSM range 160-300. A Polo t-shirt is more stylish and fashionable than a basic t-shirt.

Different Parts of a Polo T-Shirt

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

1. Collar.

2. Placket. 
3. Front part
4. Back Part
5. Left sleeve
6. Right sleeve
7. Left sleeve cuff 
8. Right sleeve cuff
9. Bottom Hem

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

SL. No.	Name of Operation	Cycle Time	Calculated Production at 100% Efficiency
1	Care Label Attach With Back Part	0.28	214
2	Placket & Body Part Matching	0.30	200
3	Placket Attach Positioning Marking	0.30	200
4	Placket Rolling	0.32	188
5	Placket Attach With Front Part	0.38	158
6	Placket Edge Cut & Tack	0.25	240
7	Half Moon Cut & Iron	0.45	133
8	Main & Size Label Attach	0.35	171
9	Half Moon Attach With Back Part	0.45	133
10	Front And Back Part Matching	0.18	333
11	Shoulder Joining	0.33	182
12	Collar Servicing	0.20	300
13	Collar Making	0.18	333
14	Collar Attach With Tape	0.36	167
15	Back Tape Top Stitch	0.30	200
16	Lower Placket Close	0.20	300
17	Upper Placket Top Stitch	0.20	300
18	Placket Box Stitch	0.32	188
19	Cuff Joining	0.42	143
20	Cuff Top Stitch	0.22	273
21	Sleeve Pair Matching With Body Part	0.38	158
22	Sleeve Joining	0.42	143
23	Arm Hole Top Stitch	0.30	200
24	Bottom Hem Stitch	0.32	188
25	Side Split Tack	0.27	222
26	Side Split Rolling & Top Stitch	0.47	127
27	Side Seam	0.57	105
28	Sleeve Close & Open Tack	0.37	162
29	Button Hole Creating At Upper Placket	0.30	200
30	Button Attach Positioning Mark At Lower Placket	0.20	300
31	Button Attach With Lower Placket	0.25	240
32	Button Push	0.18	333
33	Final Thread Cut	0.30	200
	Total Cycle Time	10.32

Table - 1: Operation Breakdown of a Polo 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.

SMV calculation of a Polo T-shirt: 

Problem: From the above table, we find total cycle time is 10.32 minute, suppose the performance rating of all operator is 85% for a Polo T-shirt. Now, Find out the SMV for that Polo T-shirt. 

Solution: 

We know,

SMV = Basic time + Allowance

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

          = (10.32× 0.85) + (Bundle allowances + machine and personal allowances)

          = 8.77 + ( 10.32 × 10%)+ (10.32 × 20%)

          = 8.77+ 1.032 + 2.064

          = 11.87

So, we find out SMV for that Polo T-shirt is 11.87 minute.

Production target calculation of a polo T-shirt:

Problem: We find SMV for that polo t-shirt is 11.87 minute. Suppose, No. of worker of that line is 44, the efficiency of that line 80%.  Find out the production target per day of that polo t-shirt in one sewing line.

Solution: 

Here,

SMV = 11.87 Minute.

No. of worker = 44.

Line efficiency = 80% = 0.80

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

                                  = { (44 × 8 × 60) / 11.87 } × 0.80

                                  = 1423.42~ 1423

                                  = 1423 pieces.

So, Daily production target = 1423 pieces in one sewing line

and Hourly production target = 1423 / 8

                                                       = 177.875~ 178 pieces / hr.
                                                       = 178 Pieces/hr in one sewing line.

Different Parts of a Polo T-shirt

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

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