What is the Time Study Formula?

Conducting a Time Study in the Garments Industry is essential for setting standard times for various operations, which helps in planning, scheduling, and improving overall efficiency. 

What is the time study formula in the garment industry? Here's a step-by-step guide on how to perform a time study for garment operations:

1. Understand the Purpose of the Time Study

• Objective: Define the purpose of the time study, such as setting standard times, improving workflow, balancing production lines, or determining labor costs.
• Operations to Study: Identify the specific operations or tasks in the garment production process that you will study (e.g., sewing a collar, attaching buttons, cutting fabric).

2. Select the Right Method

• Direct Time Study: This is the most common method, where you directly observe and time a worker performing a task.
• Work Sampling: For operations that vary greatly, work sampling may be used, where random samples of the task are observed over time.

3. Prepare for the Study

• Choose a Representative Worker: Select a worker who is representative of the average skill level for the operation being studied. Avoid extremes (i.e., a beginner or an expert).
• Gather Tools: Use a stopwatch or time study software, along with a clipboard, pen, and time study sheet to record observations.
• Break Down the Operation: Divide the operation into smaller, measurable elements. This helps in capturing accurate timings and understanding the work sequence.

4. Conduct the Time Study

• Observe the Operation: Observe the selected worker performing the operation multiple times. Ensure that the worker is performing the task under normal working conditions.
• Record the Time: Start the stopwatch as the worker begins the operation and stop it when the operation is complete. Record the time taken for each element of the operation.
• Repeat for Accuracy: Conduct multiple observations (at least 10-15 cycles) to account for variability and ensure accuracy. Calculate the average time for each element.

5. Analyze the Data

• Calculate Average Time: For each element of the operation, calculate the average time taken based on the multiple observations.
• Apply Performance Rating: Assess the worker’s performance against a standard or benchmark (e.g., if the worker was slower or faster than average). Adjust the recorded times accordingly. This is known as performance rating or leveling.
• Determine the Normal Time: Multiply the observed time by the performance rating to get the normal time for each element.

6. Calculate Standard Time

• Add Allowances: Add allowances for rest, fatigue, and any unavoidable delays to the normal time to calculate the standard time. Common allowances might range from 5% to 20% depending on the nature of the task.
• Standard Time Formula:

$$\text{Standard Time} = \text{Normal Time} + \text{Allowances}$$

• Example:
  • If the normal time for an operation is 2 minutes, and you add a 15% allowance for rest and fatigue:
  
  
  $$\text{Standard Time} = 2 \text{ minutes} \times 1.15 = 2.3 \text{ minutes}$$

7. Document and Implement the Results

• Create Standard Time Sheets: Document the standard times for each operation and distribute them to relevant departments, such as production planning and HR.
• Use for Line Balancing: Implement the standard times to balance production lines, set performance targets, and schedule work more effectively.

8. Review and Update

• Monitor Performance: After implementing the standard times, monitor actual performance to ensure they are realistic and achievable.
• Periodic Review: Periodically review and update the time study data to account for changes in processes, equipment, or worker skill levels.

9. Train Employees

• Training on Standards: Ensure that workers and supervisors are trained on the importance of adhering to the standard times and how these times are calculated.
• Feedback Loop: Encourage feedback from workers on the practicality of the standard times, and make adjustments if necessary.

10. Use Technology

• Time Study Software: Consider using time study software or apps that can automate data collection and analysis, improving accuracy and efficiency.
• Video Analysis: Record videos of operations and analyze them frame by frame to identify inefficiencies or areas for improvement.

Example of Time Study Sheet:

Tips:

• Start Small: If you are new to time studies, start with a single operation and gradually expand to more complex tasks.
• Consistency is Key: Ensure consistency in observation and data recording to maintain the accuracy of your time study.
• Involve Workers: Engage workers in the process, as they can provide insights and help in making the time study more practical and accurate.

By Conducting a Thorough Time Study, you can establish realistic and efficient standard times for garment operations, leading to improved productivity and better workflow management in your factory.