garment-line-efficiency

Sewing line efficiency calculator for garment factories.

Calculates the industry-standard SAM-based efficiency metric, target output, required worker count, and line balance / bottleneck analysis. Built and used in production by Scan ERP — the QR-based ERP that tracks line efficiency in real time on the factory floor.

Install

npm install garment-line-efficiency

Formula

Efficiency % = (Output × SAM) / (Workers × Hours × 60) × 100

Where:

• Output = pieces produced
• SAM = Standard Allowed Minutes per garment (a.k.a. SMV)
• Workers = number of operators on the line
• Hours = working hours

Example: 25 workers × 8 hours = 12,000 available minutes. Produced 200 pieces of a SAM-15 garment = 3,000 minutes earned. Efficiency = 25%.

Usage

const {
  calculateEfficiency,
  calculateTargetOutput,
  calculateRequiredWorkers,
  calculateLineBalance,
  classifyEfficiency,
} = require('garment-line-efficiency');

// Basic efficiency
calculateEfficiency({ output: 200, sam: 15, workers: 25, hours: 8 });
// → 25 (%)

// Target output for desired efficiency
calculateTargetOutput({ efficiency: 50, sam: 15, workers: 25, hours: 8 });
// → 400 pieces

// Workers needed to hit a target
calculateRequiredWorkers({ targetOutput: 500, sam: 15, efficiency: 60, hours: 8 });
// → 26.04 workers

// Line balance / bottleneck
calculateLineBalance([
  { operation: 'Shoulder join', sam: 0.5 },
  { operation: 'Sleeve attach', sam: 0.8 },
  { operation: 'Side seam',     sam: 0.6 },
  { operation: 'Hem',           sam: 0.4 },
]);
// → { bottleneck: 'Sleeve attach', maxSam: 0.8, avgSam: 0.575,
//     balanceRatio: 71.875, totalSam: 2.3, operationCount: 4 }

// Classify against industry benchmarks
classifyEfficiency(50); // → 'AVERAGE'
classifyEfficiency(70); // → 'EXCELLENT'
classifyEfficiency(80); // → 'WORLD_CLASS'

Industry benchmarks

| Efficiency % | Classification | |--------------|------------------| | < 35% | BELOW_STANDARD | | 35–50% | AVERAGE (typical for Bangladesh / India / Nepal) | | 51–65% | GOOD | | 66–75% | EXCELLENT | | > 75% | WORLD_CLASS |

Related

• garment-smv-calculator — SMV / SAM calculation
• garment-piece-rate — piece-rate payment
• garment-dhu-calculator — DHU quality metric
• garment-aql-calculator — ISO 2859-1 AQL sampling

Try Scan ERP

This calculator is free. The full ERP system that uses it every day to compute line efficiency from real-time QR-scan data — with bottleneck alerts and operator dashboards — is at scanerp.pro.

• Live demo · 1.4M+ pieces tracked
• Line efficiency guide
• Free 30-day trial

License

MIT © Santosh Rijal / Scan ERP