A.SHT 2003
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Transcript of A.SHT 2003
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About Sapphire Home Textiles:
Sapphire Home Textiles is one of the largest manufacturers and exporters of
textile products in Pakistan. Sapphire has most modern and organized textile
production setup. We have versatile stitching facility with state of the art stitching
machines and capable of stitching a wide variety of woven & knitted fabrics using
the chain system for efficient mass production. Specialized in a variety of stitches
such as, Single Needle Lock Stitch, Zigzag Stitch, Five Thread Safety Stitch, Bar
Tack Stitch, Button Hole & Button Attachment Stitch.
We are specialize in a variety of Home Textile Made ups such as Sheet Sets,
Quilt/Duvet Covers, Bed Skirts, Shams, Pillowcases, Comforters, Curtains, Table
Covers, Aprons etc. We believe in total quality from raw material, to all stages of
stitched Made-up production till delivery. Skillfully trained quality inspectors carry
out quality assurance.
Abstract/Summary/:
Stitching is the major operations in apparel manufacturing industry.
Increasing the production rate of this process without losing quality of product is
major concern of production department so that shipment date could be met. Forthe estimation of cost of making a garment SAM value plays a very important role.
On-line time study is an accurate method to determine the Standard time for
operations performed on fabric.Time study is used in order to achieve rational and
reasonable results for costing of Stitching operations. In the following paragraphs
stitching cost has been estimated for assigned articles.
Customer: Harbor
Article: Flat Bed Sheet
Dimensions: 70x115 Inches
PO
FabricQuality
Design
ReadySize
CutSize*
Quantity
Direction
C.F FabricRequired
FabricWidth
40x40/130x58
Percale
70x115
72x120
28800 WxL 1.82 52416 mtr 120
*with top hem of 3 & bottom hem of 1
Operations: Three operations are used.
Sapphire Textile Mills Ltd.
http://www.onlineclothingstudy.com/2011/02/garment-cm-cost-estimation-using-sam-or.htmlhttp://www.onlineclothingstudy.com/2011/02/garment-cm-cost-estimation-using-sam-or.html -
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1- Top hem
2- Bottom hem
3- Side hem
All these operations are carried out on three separate stations with the help ofsingle needle lock stitching machine.
Thread Consumption:
Lock stitch length working = 72+72+115+115 = 374
Thread utilized per inch = 3.5
Thread consumed = 3.5 x 374 = 1309 =33.25 meters
For 28800 pieces = 33.25 x 28800 = 957600 meters
Total Thread Required = 1005480 meters
No. of large cones Required = 1005480/ 5000 = 201.1 cones
Thread cost = 201.1 x 193 = 38812.3 Rs.
Cost of Thread per Piece = 1.347 Rs.
Time Study For Flat Bed Sheet:
1st operation
Top hem
2nd operation
Bottom hem
3rd operation
Side hem
Time Rating Time Rating Time Rating
Operator 1
Operator 2
Average time
Standard time
SAM
Note:
For single lock stitch daily wage: 500
For single lock stitch per minute cost(SMV): 500/480 = 1.04 Rs.
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1- Top hem
SAM = 29.04 = 0.484 min
SMV = 500/480 = 1.04Operation cost per pc = SAM SMV = 0.484 1.04 = 0.50 Rs.
For 28800 pcs = 14400Rs.
No. of products processed in 8 hrs = 991 pcs
2- Bottom hem
SAM = 33 sec = 0.55 min
SMV = 1.04 Rs/min
Operation cost per pc = SAM SMV = 0.55 1.04 = 0.572 Rs.
For 28800 pcs = 16473.6 Rs.
No. of products processed in 8 hrs = 872.7~872
3- Side hem
SAM = 77.88 = 1.29 min
SMV = 1.04 Rs.
Operation cost per pc = SAM SMV = 1.29 1.04 = 1.342 Rs/min
For 28800 pcs = 38649.6 Rs.
No. of products processed in 8 hrs = 369.8~369 pcs
From above calculations it is clear that station # 3 is our bottle neck station. It isprocessing minimum number of products. We can produce only 369 completedproducts on a single line. Even if we increase no stations for last operation, still theycannot meet the production of their succeeding operations. But a small inventorybetween the stations is desireable for inspection and trimming operations.
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Accessories Cost:
Cost of labels =
Cost of label joining with each other =
Electricity cost:Machine power = 400 W
Tube Lights Wattage = 40+40+14= 94 W
Total Wattage = 494 ~500 W
Time taken for consumption of one unit = 1KWh/ Wattage = 1000/ 500 = 2 hrs. =120 min
Cost per min = Price of one unit of power/ time for one unit = 11/120 = .092 Rs.
Line Balancing:
Customer: Harbor
Article: Pillow Case
Dimensions: 2030 inches
PO FabricQuality
Design
ReadySize
CutSize*
Quantity
Direction
C.F
FabricRequired
FabricWidth
37536
40x40/130x59
Percale
20x32 21x71
720 WxL 0.36
259.2 mtr 105
*with 3 hem on opening
Operations: Two operations are used.
1- Opening Hem
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2- Side Safety Stitching
Single needle lock stitch machine is used for hemming and 5 thread safety stitchingis carried out to mould it into U-shape.
Thread Consumption:
Lock Stitch working = 21+21=42
Thread utilized per inch for single lock stitch = 3.5
Thread consumed = 3.5 x 42 = 147
Side Lengths = 30+30 = 60
Thread utilized per inch for safety stitch = 20
Thread consumed = 20x 60 = 1200
Total thread consumed per Piece = 1200+147 = 1347 = 34.214 meters
Thread consumed for 28800 pieces = 34.214 x 28800 =985363.2 meters
Total thread required = 1034631.4 meters
No. of large cones required = 1034631.4/ 5000 = 206.93~ 207
Cost of one cone = 193 Rs.
Cost of thread consumed = 193 x 207 = 39951 Rs.
Cost of thread for one product = 1.38 Rs
Time Study For Pillow Case:
Ist operationTop & bottom hem
2nd operationSide safety
Time Rating Time Rating
Operator 1
Operator 2
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Average time
Standard time
SAM
For single lock stitch daily wage: 500
For single lock stitch per minute cost(SMV) 500/480 = 1.04 Rs.
For safety stitch daily wage: 550
For safety stitch per min cost (SMV): 550/480 = 1.15Rs.
1- Top & bottom hem
SAM = 20.46sec = 0.341 min
SMV = 1.04 Rs.Operation cost per pc = SAM SMV = 0.341 1.04 = 0.35 Rs.
For 28800 pcs = 10080 Rs.
No. of products processed in 8 hrs = 1407 pcs
2- Side Safety over lock
SAM = 43.05 sec = 0.72min
SMV = 1.15 Rs.
Operation cost per pc = SAM SMV = 0.721.15 = 0.828 Rs.
For 28800 pcs = 238464.4 Rs.
No. of products processed in 8 hrs = 666 pcs
Time taken by one product = 0.34+ 0.72= 1.06 min
Available time = 8 hrs= 480 min
Total product made in 8 hours = 452
Accessories Cost:
Cost of labels =
Cost of label joining with each other =
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Electricity cost:
Machine power = 400 W
Tube Lights Wattage = 40+40+14= 94 W
Total Wattage = 494 ~500 WTime taken for consumption of one unit = 1KWh/ Wattage = 1000/ 500 = 2 hrs. =120 min
Cost per min = Price of one unit of power/ time for one unit = 11/120 = .092 Rs.
Line Balancing:
Recommendations/ Suggestions/ Findings: