Industrial Engineering, Time & Motion

Industrial Engineering, Time & Motion 18

• Living Wage Gap & Compliant Hours Costing Premium Costs the two demands that arrive together - bring hours within the code, and close the gap to a benchmark living wage - as the separate decisions they are. Reports what compliant hours take off the payslip before any wage rise is considered, then what closing the gap from that point costs per garment and as a share of the export price. Cost of Closing the Gap, per Garment cost/pc
• Operator Attrition Cost & Retention Payback Premium Prices labour turnover at what it actually costs rather than at what recruitment invoices: the replacement arrives below the efficiency of the operator who left and climbs for weeks, and those unearned standard minutes are the larger part of the bill. Costs it by section, and tests whether a wage increase pays for itself by returning the attrition rate it would have to reach. Annual Cost of Turnover cost
• Permanent or Contract: Sizing a Roll Against a Seasonal Book Premium Sizes the permanent roll against a month-by-month order book rather than against its average, charging contract labour at the productivity it actually delivers and charging permanent heads in the months there is nothing for them. Returns the headcount that costs least, what the average and the peak cost instead, and the number of months a head has to be busy before employing it beats hiring it. What Sizing the Roll Right Saves cost/yr
• Sewing Line Balance Board Premium Turns an operation bulletin into the figure the line will actually make: the bottleneck station sets the rate, and every other operator waits on it. Reports line efficiency and balance loss, prices the idle minutes as the wage bill they are, and answers the inverse question of how many operators each operation needs to reach a target output. Output per Shift pcs
• The Absence Rate, and the Output It Actually Costs Premium Runs a sewing line as the chain it is, so absence is costed where it binds rather than averaged across the plant. Reports the absence percentage beside the output percentage it destroys - two figures that are equal only by accident - says which operation actually binds once people are missing and whether that is a different one from a full day, and works out how many reserves are worth carrying by buying them only while the output they recover beats the wage they cost. Output Lost to Absence %
• The Price per Kilogram You Buy At, and the Cost per Metre You Weave At Premium Converts each yarn quotation into the currency the mill actually sells in: derives loom efficiency from the break rates and repair times the yarn causes, prices the loom hours it consumes alongside the yarn itself, and ranks the offers by cost per metre of cloth. Then converts back, giving every yarn the price per kilogram it would have to be quoted at to justify itself - a figure a supplier can argue with. Cost a Year of Buying the Cheapest Quote cost
• What an Overtime Piece Actually Costs, Against What the Multiplier Says Premium Costs each overtime block on the output it produced rather than the hours it was paid for, using the line's own recorded efficiency and defect rate, and reports the effective multiple against the same line on regular hours - then names the blocks where the pieces cost more than subcontracting them would have. Effective Cost Multiple x
• What the Spares Store Is Worth, and What It Is Actually Protecting Premium Prices a whole spares store on the one distinction that matters - a stoppage with the part on the shelf lasts as long as the repair, and without it as long as the supply - then reports coverage twice: the share of listed parts that have stock, and the share of the production at risk that the stock genuinely protects. Ranks every line by what one more unit on the shelf would save against what it costs to carry. Coverage of What Is at Risk %
• Where the Shift Went Premium Splits a ring frame shift's shortfall into the four causes that can be acted on separately - running under the designed speed, idle spindles, downtime and waste - and reports what is left unexplained rather than distributing it. Takes one row per frame from the shift sheet a mill already keeps. Shortfall Against What the Frames Could Have Made kg
• Which Shift Earns Its Keep Premium Costs each shift on what stops when it stops, rather than on a share of costs that carry on regardless. Reports the price at which each shift stops earning its keep, ranks the shifts by which is genuinely cheapest to run, and prices the contribution a mill throws away by shutting shifts that only look unprofitable on an absorbed cost. Contribution at Risk From Absorbed-Cost Thinking cost/yr
• Bundle Ticket Tracking & Piece-Rate Wage Modeler Converts completed bundle tickets into operator earnings: pieces completed, standard minutes earned, shift efficiency, base piece-rate pay, efficiency bonus above the threshold, the payable amount against the guaranteed wage and the effective hourly rate. Shift Earnings /shift
• Cut-to-Box Lead Time & Stage WIP Velocity Calculator Measures how long a cut panel takes to become a packed garment: dwell time in cutting, sewing, finishing and packing separately, total cut-to-box lead time in days and hours, and the share of floor inventory sitting at the worst stage. Cut-to-Box Lead Time days
• Factory Floor Spaghetti Diagram Distance-to-Cost Converter Converts material movement into labour cost: time per trip from distance and handling, daily minutes and distance walked, daily and annual cost of the movement, the share of trip time that is walking, and the saving a target distance reduction would deliver. Annual Cost of Movement /year
• Operator Fatigue & Delay Allowance Ergonomic Modeler Derives a PF&D allowance from the physical work rather than a flat rate: fabric mass handled per cycle, fatigue allowance from that mass, a reach penalty beyond the comfortable envelope, the total allowance, allowed time and the minutes it consumes per shift. Total PF&D Allowance %
• Sewing Needle-Time vs Material Handling Ratio Optimizer Splits a sewing cycle into machine and handling time: actual stitching time from seam length and effective machine speed, total cycle, needle-time and handling shares, and the gain available from doubling machine speed against shaving a tenth off handling. Needle Time Share %
• Stand-up vs Sit-down Modular Cell Output Predictor Models converting a seated line to standing modular cells: adjusted SMV after reduced handling and increased fatigue, output per shift both ways, the output gain, work-in-progress removed and lead time before and after. Output Gain %
• Synthetic SMV Builder from MTM-2 Motion Elements Builds a sewing standard minute value from motion elements without a time study: TMU for GET and PUT motions at the working distance, total motion time, basic time including machine time, the allowed SMV and output per hour. Synthetic SMV min
• Work-Cell Polyvalence & Factory Flexibility Index Quantifies cross-training depth and absence resilience: polyvalence index from the skill matrix fill rate, average skills per operator, trained operators per operation, expected availability after absenteeism, the minimum training required for coverage and the redundancy factor achieved. Polyvalence Index %