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Why Your Line Efficiency Is Low - Identify The Reasons

The document identifies several potential reasons for low line efficiency in a factory, such as dry lines causing idle time, quality issues stopping production, long set-up times between styles, imbalance in the production line, operator absenteeism, employees working off-standard jobs or with low skills, and uncounted lost time not being tracked. It encourages analyzing efficiency data and production processes to determine the root causes of low efficiency specific to each factory, such as identifying why standard times are not being met and where that time is being lost.

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Esubalew gebrie
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34 views6 pages

Why Your Line Efficiency Is Low - Identify The Reasons

The document identifies several potential reasons for low line efficiency in a factory, such as dry lines causing idle time, quality issues stopping production, long set-up times between styles, imbalance in the production line, operator absenteeism, employees working off-standard jobs or with low skills, and uncounted lost time not being tracked. It encourages analyzing efficiency data and production processes to determine the root causes of low efficiency specific to each factory, such as identifying why standard times are not being met and where that time is being lost.

Uploaded by

Esubalew gebrie
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Why Your Line Efficiency is Low -

Identify the Reasons

Compiled By: Esubalew Gebrie


Addis Ababa, Ethiopia
December ,2013 E.C
Let’s check the fact.
Let’s assume the average line efficiency of your factory is
60% (Monthly average).
How the balance 40% standard time is lost? Where that
40% of the standard time is gone? (The efficiency data
might be different to your factory).
You need to study the fact, analyze data and find out the
root causes for having low efficiency.
Ask these questions to yourself and note down the answers
to identify the reasons how a factory loss line efficiency. 
Cont.….
 A dry line - Do you often find that most of the
operators in the line sit idle due to a shortage of
feeding?
 Idle times - Do you see operators sit idle for some
reasons? If so what are the reasons?
 Quality issues - Do you need to stop operators if they
are not making desired quality? Do you send the
defective garments back to the line for repair work?
Does it build a bottleneck in the line? Think of an
alternative way of repair work?
Cont.….
 Set-up efficiency loss - Does your line takes too
much time to set up it for a new style?
 Balancing loss /Imbalance line - How much time
you lost due to balancing loss in the OB?
 Operator absenteeism - Do you often see some of
your operators are absent? Do you have enough
floaters in the place of the absentees? What you do to
reduce the absenteeism rate?
 Off-standard work - Do you need to move operators
from their job to another job on which they don’t have
the skill?
Cont.….
 Low employee morale – Money is one of the best
motivators to motivate workers and employees and it works.
Do you have a performance incentive scheme for the shop
floor workers?
 Overtime work - It is a common practice that many of us
work 2-3 hours after regular shifts. Does the excess overtime
reduce operator’s performance? Think – can you stop
working overtime by producing daily target qty within the
regular shift hours?
 Low skilled operators – How many of the employees do not
have the required skill? Do you have any plan to train them?
 Uncounted time – Do you have the record of all lost-time
 hours? How much time is not counted in the lost efficiency?
o u !
nk y
Tha

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