MAN TO MACHINE RATIO (MMR) & FORMULA IN GARMENTS INDUSTRY

MAN TO MACHINE RATIO (MMR) 

The man to machine ratio is an important KPI in manufacturing sector. The same is applied in apparel manufacturing. I would like to explain the term man to machine ratio (MMR), it’s importance and method to calculate man to machine ratio.

MMR

WHAT IS MAN TO MACHINE RATIO (MMR) 

Man to machine ratios is defined as the total workforce in a factory to the total number of operational sewing machines.

MMR widely varies depending on the Organization structure, quality system and the level of automation used in the processes. If a factory has only production related departments (cutting, sewing, maintenance, quality and IE) then the ratio will be low. On the other hand, if a factory includes manpower from the departments like product design and development, sampling to finishing to shipment and documentation then the ratio will be high.

WHY TO MAN TO MACHINE RATIO (MMR) 

🔹 By measuring the ratio, factory management assesses how many personnel are employed per machine. This ratio gives a clear indication of indirect cost ratio against the direct labour cost of a company.

🔹 MMR analysis is done to control overhead cost, every employees and workers cost to a company whatever their salary is. Note that different factories may have different MMR based on the factory size.

🔹 Factories those measure this ratio and use it to control cost have a bench mark man to machine ratio. When MMR increases in a specific month, factory checks where manpower increases.

🔹 Manpower may increase in sewing floor such as marking man, press man and helpers or number of staff. Department heads need to confirm if that additional manpower is required need to confirm if that additional manpower is required permanently or required is of style basis. According to that new MMR is updated.

🔹 MMR is measured to check factory’s MMR and compare it with the industry benchmark.

HOW TO CALCULATE MAN TO MACHINE RATIO (MMR) 

To measure MMR of a factory:

🔹Count total number of employees working in the factory(include all manpower)

🔹 Count total number of active sewing machines, consider only operational sewing machines that are being used in a current month.

For Example:

1) in a factory, total 1000 manpower is employed and the total operational sewing machine count is 500 number.

Therefore,

Man : Machine
= 1000 : 500
= 2 : 1 (or MMR is 2)


2) if total manpower employed in a factory is 800 and the total operational sewing machines are 500.

Therefore,

Man : Machine
= 800 : 500
= 1.6 : 1 (or MMR is 1.6)