This document provides details about production planning for a dungaree skirt, including: - Standard minute value (SMV) is calculated as 22.92 minutes based on basic and allowance times. - Pitch diagram shows minor bottleneck at operation 7. - Hourly capacity is 188 pieces and daily capacity is 1885 pieces. - Targets are set to complete a 10,000 piece order within 11 days based on varying hourly and daily efficiencies from 30-70%. - Efficiency and productivity are calculated from actual production data on the 5th day of 70.03% and 57.83 respectively.

1. Contents:
• Details about Dungaree
• Operation Bulletin of a Dungaree Skirt
• SMV
• Pitch Diagram
• Capacity
• Target
• Schedule Making
• Calculation of Day requirement
• Efficiency
• Productivity

2. What is Dungaree ?
Dungaree fabric is a historical term
for an Indian coarse thick 2/2 twill-
weave cotton cloth, often colored
blue. Which is now known as blue
denim.
Dungaree is the work trousers or
overalls made of this cloth. It is a
pair of trouser or skirt with an extra
piece of cloth that cover the chest
and held in place by a strap over
each shoulder.

3. History Of
Dungaree:
Dungaree was mentioned for the first time in 17th century, when it was
referred to a cheap, coarse, thick cotton cloth.
Dungarees are thought to have been named after Dongari Kapar, a harbor
side village near Mumbai in India where a coarse, thick calico was
manufactured.
The Hindi name for this cloth was “dungri".
Along the way an extra syllable was added and "dungri" became
"dungaree".
There are records of "dungaree" cloth, in the English language, dating
back to 1605.
Durable and cheap the "dungaree" cloth was exported to England.
The cloth, often indigo-dyed, was used to make robust overalls - worn on
ships and by farm workers in the fields.
Gradually "dungaree" transferred from the name of the cloth to denote
instead the style of the overalls – a pair of trousers held up with a bib and
shoulder straps.
During the First World War women took over much of the factory work,
and adopted the uniform – a handy pair of dungarees, perfect protection
against the oil and grease.
Dungarees have since entered the mainstream.
Just now they are undergoing a huge resurgence – perhaps because they
are so comfortable, easy and fun to wear.

4. Types of Dungaree

5. Operation Bulletin
Operation Bulletin Of Dungaree Skirt

6. Basic data
given on
Operation
bulletin
• Helper=9
• Iron Man=6
• Operator=57
• Total manpower=72
• Total SMV= 22.92

7. WHAT IS
SMV?
SMV is defined as the time which is
allowed to perform a job satisfactorily.
Normally it is expressed in minute value.
The full elaboration of SMV is Standard
Minute Value. SMV term is broadly used
in the garments manufacturing industry.
SMV is also known as Standard Allocated
Minute (SAM). For smooth and timely
shipment an export order a merchandiser
need to proper SMV set up in garments
production floor.

8. Formula for
SMV
calculation
• SMV=BASIC TIME +Allowance% on BT
• Basic Time=Observe time X Rating%
• Observe Time=Average cycle time
Average cycle time =Total Process
cycle/number of cycle
In the operation bulleting SMV given 22.92.

9. PITCH
DIAGRAM
• Pitch diagram is a graphical presentation
of individual operation’s time(SAM) and
pitch time on a same chart is called pitch
diagram.

10. Pitch Diagram
calculation
• Formula:
• Basic Pitch Time (B.P.T)= Total Product SMV/
Total Number of Manpower
• Upper Control Limit (U.C.L)= B.P.T/0.85
• Lower control Limit (L.C.L)= (2XB.P.T)-U.C.L
• B.P.T=22.92/72
=0.3183
• U.C.L= 0.3183/0.85
=0.3745
• L.C.L=(2X0.3183)-0.3745
=0.2621

11. Comments:
Bottleneck minor 7, line is imbalanced

12. Capacity
Calculation
Calculation of production capacity for a
garment factory is an important issue in
readymade garments sector. The
production time of an order is directly
proportional to the vendor’s production
capacity. Production planning department
must be inform forecast capacity order to
merchandisers & management so they can
inform to buyer for order.

13. Formula
For
Capacity
Calculation
• Capacity =
𝑊𝑜𝑟𝑘𝑖𝑛𝑔 𝑀𝑖𝑛𝑢𝑡𝑒
𝑆𝑀𝑉𝑋𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑆𝑀𝑉 𝐸𝑎𝑟𝑛𝑒𝑟𝑠
𝐻𝑜𝑢𝑟𝑙𝑦 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦 =
1𝑋60
22.92𝑋72
= 188.48
= 188 PCS.
𝐷𝑎𝑖𝑙𝑦 𝐿𝑖𝑛𝑒 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 =
10𝑋60
22.92𝑋72
= 1884.81
= 1885 PCS.

14. TARGET
• Production quantity produced by a
qualified worker in a day at standard
performance is known as daily
production target

15. Hourly Line Target
• Formula:
Hourly line target= hourly line Capacity X
Efficiency
Hourly Line Target:
Day1 @ 30%=188X30%=56.4=56
Day2 @ 40%=188X40%=75.2=75
Day3 @50%=188X50%=94
Day4 @60%=188X60%=112.8=113
Day5 @70%=188X70%=131.6=132

16. Daily Line
Target
Daily line target= Daily Line capacity X
Efficiency
• Day1 @ 30%=1885X30%=565.5=566
• Day2 @ 40%=1885X40%=754
• Day3 @ 50%=1885X50%=942.5=943
• Day4 @ 60%=1885X60%=1131
• Day5 @ 70%=1885X70%=1320

17. Schedule
Making
• Order quantity 10,000 PCS
• Wastage 5%
• Production start date 10th of July 2014
𝐷𝑎𝑦 𝑅𝑒𝑞𝑢𝑖𝑟𝑒𝑑 =
𝑇𝑜𝑡𝑎𝑙 𝑜𝑟𝑑𝑒𝑟 𝑞𝑢𝑎𝑛𝑡𝑖𝑡𝑦 + 𝑊𝑎𝑠𝑡𝑎𝑔𝑒
𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝑑𝑎𝑖𝑙𝑦 𝑡𝑎𝑟𝑔𝑒𝑡
Average Efficiency = Sum of all Efficiency/Number of
efficiency
𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦
=
30% + 40% + 50% + 60% + 70%
5
= 50%
Average daily target = Capacity X Average Efficiency
= 1885X50%
= 942.5
= 943

18. Calculation
of day
requirement
𝐷𝑎𝑦 𝑅𝑒𝑞𝑢𝑖𝑟𝑒𝑑
=
𝑂𝑟𝑑𝑒𝑟 𝑄𝑢𝑎𝑛𝑡𝑖𝑡𝑦 + 𝑊𝑎𝑠𝑡𝑎𝑔𝑒
𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝑇𝑎𝑟𝑔𝑒𝑡
= 10,000+5%/942
=10500/942
= 11.15 Days

19. Schedule of Target quantity
SL DATE DAY TARGET CUMULATIVE BALANCE
10,500
1 10 July 2014 Tuesday 566 566 9,934
2 11 July 2014 Wednesday 754 1,320 9,180
3 12 July 2014 Thursday 943 2,263 8,237
4 13 July 2014 Friday
5 14 July 2014 Saturday 1,131 3,394 7,106
6 15 July 2014 Sunday 1,320 4,714 5,786
7 16 July 2014 Monday 1,320 6,034 4,466
8 17 July 2014 Tuesday 1,320 7,354 3,146
9 18 July 2014 Wednesday 1,320 8,674 1,826
10 19 July 2014 Thursday 1,320 9,994 506
11 20 July 2014 Friday
12 21 July 2014 Saturday 506 506
13 22 July 2014 Sunday
14 Monday

20. Efficiency:
The efficiency formula is used for
measuring batch production efficiency and
workers' production efficiency. The
efficiency is the work output from an
operation, divided by work input from the
same operation, and expressed as a
percentage.
Efficiency=
𝑇𝑜𝑡𝑎𝑙 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝑋 𝑆𝑀𝑉
𝑁𝑜.𝑜𝑓 𝑆𝑀𝑉 𝐸𝑎𝑟𝑛𝑒𝑟𝑠 𝑋 𝑊𝑜𝑟𝑘𝑖𝑛𝑔 𝑀𝑖𝑛𝑢𝑡𝑒
X100

21. Data for
Efficiency
Calculation:
Production = 1320 PCS
SMV=22.92
Total Manpower = 72
Working Hour = 10
Efficiency=
1320𝑋22.92
72 𝑋 10𝑋60
X 100
= 70.03%

22. Productivity
Calculation
Productivity is a ratio to measure how well
an organization (or individual, industry,
country) converts input resources (labor,
materials, machines etc.) into goods and
services. Productivity measurement is both
a measure of input utilization and an
assessment as to whether or not input
utilization is growing faster than output.
Productivity Formula = Output / Input

23. Productivity
Calculation
Data is Given:
Production = 1320 Pcs ( according to 5th day )
Working Hours = 10
Machine = 57
Manpower = 72
Per Hour production = 1320/10 = 132
Per Machine = 1320/57 = 23.16
Manpower = 1320/72 = 18.33
Average Line productivity = (132+ 23.16 +
18.33 )/3
= 57.83

24. Recap:
• SMV 22.92
• Pitch diagram shows 7 minor bottleneck.
• Hourly line capacity 188 PCS and Daily
line capacity is 1885 PCS.
• Hourly line target 132 PCS on day 5 and
daily line target 1320 PCS on day 5.
• Total day required 11.15 days but target
quantity completed within 10 days.
• Efficiency 70.03%
• Productivity 57.83

25. Thank You