Man Machine Ratio (MMR) shows how many employees a factory needs for every running sewing machine. It is a quick indicator of manpower cost: the lower the MMR for the same output, the fewer people you pay for each machine.
Formula: MMR = Total employees ÷ Running machines
"Total employees" can be counted at different levels, so always say which one you use:
| Level | Who is counted |
|---|---|
| Direct MMR | Operators + helpers on the line |
| Floor MMR | Everyone on the floor, including supervisors, QC, IE, maintenance |
| Factory MMR | All employees, including support departments |
Example: a floor has 420 operators, 110 helpers and 45 supervisors, QC and other staff, with 480 running machines.
- Floor MMR = (420 + 110 + 45) ÷ 480 = 1.20
- Direct MMR = (420 + 110) ÷ 480 = 1.10
What drives MMR up
- Too many helpers for manual work that could be done with attachments or folders
- Absent operators covered by extra people instead of multi-skilled operators
- Idle machines kept "running" in the count while no one uses them
- Extra checkers because quality problems are caught too late
How to improve it
- Method development: folders, guides and attachments remove manual helper work.
- Multi-skilling: operators who can run two or three machine types cover absence without extra hires.
- Better balance: fewer idle operators waiting for work.
- Inline quality: find defects at the machine instead of adding end-line checkers.
Tip: Track MMR together with efficiency. Cutting helpers can lower MMR but also drop output if the work does not disappear.
Try it in the free MMR calculator.