Understanding Beat Time and Cost Calculation

Understanding Beat Time and Cost Calculation

What is a Beat?

A beat occurs whenever an employee scans a batch on the device. The system records a beat, knowing the batch, order, style, and all related information using the RFID tag of the scanned batch. Additionally, the system knows the employee and processes from the assignment on the device. This information allows the system to calculate beat time and cost accurately.

Scenario 1: Basic Scenario

  1. Single Process Assignment: An employee is assigned to a device with only one process.
  2. Batch Details: The batch quantity is 30 pieces.
  3. Time Stamps: The employee's last scan was at 10:20 AM, and this scan is at 10:30 AM, resulting in a total of 10 minutes.
  4. Estimated Time: The process has an estimated time of 0.25 minutes per piece, so it should take 7.5 minutes to finish 30 pieces.
  5. Actual Time: It actually took 10 minutes, making the actual beat time per piece 0.33 minutes.
  6. Result: The efficiency of the employee is decreasing as the actual time is slower than the estimated time.

Scenario 2: Batch Group

  1. Batch Group Details: Contains 3 batches: Batch 1 (10 pieces), Batch 2 (15 pieces), Batch 3 (15 pieces).
  2. Time Stamps: The last scan was at 11:00 AM, and this scan is at 1:00 PM, resulting in 120 minutes.
  3. Estimated Time: The process has an estimated time of 1.5 minutes per piece. So this means each batch should take
    1. Batch 1: 15 minutes
    2. Batch 2: 22.5 minutes
    3. Batch 3: 22.5 minutes
  4. Actual Time: Total time is 120 minutes for 40 pieces, making it 3 minutes per piece.
    1. Batch 1: 30 minutes
    2. Batch 2: 45 minutes
    3. Batch 3: 45 minutes
  5. Result: The actual time is much slower than estimated, indicating a significant decrease in employee efficiency.

Scenario 3: Break Time Inclusion

  1. Same as Scenario 2: With a break time from 12:00 PM to 12:30 PM.
  2. Adjusted Time: Total time is 90 minutes instead of 120 minutes after subtracting the 30-minute break.
  3. Actual Time: Total time is 90 minutes for 40 pieces, making it 2.25 minutes per piece.
    1. Batch 1: 22.5 minutes
    2. Batch 2: 33.75 minutes
    3. Batch 3: 33.75 minutes
  4. Result: Better than Scenario 2 but still needs improvement.

Scenario 4: Multiple Processes

  1. Multiple Processes: Employee works on multiple processes simultaneously.
  2. Batch Details: Batch of 10 pieces.
  3. Time Stamps: The last beat was at 1:00 PM, and the next one is at 1:20 PM, resulting in 20 minutes.
  4. Estimated Time:
    1. Process 1: 2 minutes per piece (20 minutes for the batch)
    2. Process 2: 1 minute per piece (10 minutes for the batch)
  5. Actual Time: 20 minutes total.
    1. Process 1: Actual time is (20/3)*2 = 13.3 minutes (1.3 minute per piece)
    2. Process 2: Actual time is (20/3)*1 = 6.67 minutes (0.67 minutes per piece)
  6. Result: The actual times for each process are calculated in proportion to the total actual time. The employee's efficiency is higher because they produced at a faster rate than estimated.

Important Notes:

  1. Break and Idle Times: Subtract any break times, idle times, or maintenance times from the total time between two beats, as the employee was not producing any pieces during these periods.
  2. Complex Scenarios: Real-life scenarios often involve multiple processes and break times. This guide provides the basics of beat time calculation, but the system can handle more complex scenarios.


    • Related Articles

    • Understanding Different Times

      In this guide, we will define and exemplify different time-related terms to help you understand how worker productivity and efficiency are measured and managed. Shift Hours Shift hours are the total time scheduled for a worker's shift, from the start ...

    • Calculating Standard Allowed Minutes (SAM) Through Time Study

      Understanding SAM in Garment Manufacturing Standard Allowed Minute (SAM) is a pivotal metric utilized in the garment manufacturing industry, serving as the time benchmark for the completion of a sewing operation. This metric is instrumental for: ...

    • Understanding Idle time

      Definition of Idle Time it is a period of time in which an employee is ready and available, but is not doing anything productive due to circumstances that are beyond their control or abilities. The cycle of requesting an idle time The employee makes ...

    • Direct Cost

      Direct Cost: is the cost that is directly affecting the production process which is basically the salary of the employee that is working on a machine and is producing output. And this is calculated by knowing the rate of the employee per day. This ...

    • Understanding Processes

      This guide is structured to help users understand the key concepts and steps needed to add processes into our system accurately and effectively. By the end of this guide, you'll have a clear understanding of the difference between style categories ...