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Break Even Analysis of Apparel Industry

Break Even Analysis of Apparel Industry

Break Even Analysis is one of the most popular and effective tools of cost volume and profit analysis. By using this we can calculate production quantity/sales quantity and their values whether there is a situation of neither profit nor loss. Apparel Industry is growing in India, Bangladesh, Vietnam, and the future of the apparel industry is very much competitive and challenging. Every year new modern garments factories are establishing to produce different garments to meet the worldwide increased demand for apparel. Here in this article, you will learn why break even analysis of apparel industry is required.

As an investor, you must be careful about making an investment decision. The main concern should be the minimization of the production cost of garments and increasing the production of garments. Different project appraisal techniques like; cost-benefit analysis, break-even analysis, capital budgeting, etc. are used by the entrepreneur or manager to make the right financial decision. Normally the company is not aware of the break-even point if it is running a profit. But in the case of losing concern, the company must try to avoid loss situation to ensure the survival of the company. Break-even point analysis is also known as BEP analysis.

Calculation Break Even Point and Analysis of Apparel Industry

To calculate breakeven quantity or value, you will be required to have the following information:

  1. Sales Price Per Unit
  2. Total Sales Quantity/ Expected Sales Quantity
  3. Variable Cost Per Unit
  4. Total Fixed Cost

If you have a total sales amount and quantity of sales, then you can easily get the average per-unit sales price by dividing the sales amount with the sales quantity. Another thing is if your company produce many varieties of products and there is a far difference in price then it will be good for you to choose a weighted average sales price instead of calculating average sales price.

On the other hand, the variable cost per unit is the amount of cost which remains fixed for any level of production or sourcing.

For your better understanding, I am giving a simple example of break-even analysis in details.

Break-Even Analysis Equation or Formula

Break Even Formula

Two basic formulas of break-even analysis are most popular, one is used for calculating the break-even quantity and another one is for break-even values.

Break Even (Quantity) = (Total Fixed Expense)/(Sales Price Per Unit-Variable Cost Per Unit)

Contribution Margin Per Unit = Sales Price Per Unit – Variable Cost Per Unit

Total Contribution Margin = Total Value of Sales – Total Variable Cost

Break Even (Dollar) = (Total Fixed Expense)/(Contribution Margin Ratio)

Contribution Margin Ratio (CM Ratio) = (Total Contribution Margin)/(Total Sales)

Break Even Analysis Example

break even analysis graph

In this break-even graph, you can see that with the increase in sales volume fixed cost remains the same for a particular period but the total cost is increasing. Total cost includes fixed cost and variable cost. Only increase of variable cost is there with the increased in production or sales. Here the thing is when you increase the sales, per unit fixed cost, will be reduced but total fixed cost remains the same. Fixed cost is shown by the straight horizontal line in the graph. On the other hand per unit variable cost will remain unchanged but the total variable cost will increase. So there is a relationship between cost, sales quantity, break-even unit, and profitability.

Calculation of Break-Even Point

Suppose you are the manufacturer of T-shirt. You want to calculate break-even quantity and value (USD) for a particular year. So that you can determine your minimum requirement of production to run your factory at profit. Based on the following information when you put the values in the above formulas you will get the value of break-even point.

  • Sales Price Per Piece: 1.6 USD
  • Variable Cost Per Piece: 1.01 USD
  • Total Fixed Cost: 500,000 USD
  • Sales (Quantity): 1,000,000 Piece
  • Total Sales: 1,600,000 USD
  • Contribution Margin Per Unit: 0.59 USD
  • Total Contribution Margin: 590,000 USD
  • Contribution Margin Ratio: 0.37
  1. Break Even (Quantity): 847,458 Piece
  2. Break Even (Value): 1,355,932 USD

Here, the break-even quantity is 847,458 piece, this means you have to produce this number of the T-shirt to remain a situation where there is no profit and loss. On the other hand, you need to sale total of 1,355,932 USD. If you can sell more than this then you will get profit. That is in addition to your break-even there will be an addition to your profit amount. So this is an easy way to set the target of your factory.

Break-Even Analysis Excel Template

I have developed a simple break-even analysis excel template for your better understanding and which is available for free use. You can use the excel template as a break-even calculator. All you need to input the values of cost and sales. If you want to get this then please comment with your email.

Calculate Garments Break-Even Production

There is no such difference among the BEP calculation and analysis of the different industry. The same methodology is applicable to the apparel industry and others. So to calculate garments break-even unit or value, same formula mentioned above you can use. All you need to gather information on your garments annual fixed cost, weighted average sales price and per unit variable cost. If you do not know how to calculate the weighted average cost then please let me know. I will write a detailed article on it.

Garments Break-Even Analysis

Analysis of Garments BEP is obvious for new garments industry or running company which is finding it hard to make a profit or incurring losses. Whatever result you will get from the calculation to find out the BEP unit or the amount you can decide what should be your target. Moreover, this will help to make the right economic decision for your factory. If you have any question regarding break-even point analysis of apparel industry then please contact with me. I can help you to calculate break-even for your whole factory, parts of the factory, machine or a production floor.

Written by
Md. Nahian Mahmud Shaikat

Ginning: Cotton Ginning, Process, Types, and Objectives

Ginning: Cotton Ginning, Process, Types, and Objectives

What is Ginning? To answer the question what is ginning? I would say, the process by which the fibers are separated from the seeds is called ginning. Human using cloth for the last seven thousand years. From the beginning, the cotton fiber is manually processed by hand until the 18th century. When automated cotton the processing machine was invented that time ginning process become so easy. Here we will discuss Ginning: Cotton Ginning, Process, Types, and Objectives.

It is one of the most important steps of the spinning process. After collecting seed cotton from the field, cotton moves to nearby gins for separation of lint, seed and any other foreign particles. The production of a typical gin is about 12 bale per hour (here 1 bale = 500 pounds). Earlier the ginning process is to be done by manually but right now for higher production, manufacturers use an automated machine with higher productivity. The machine is well known as a cotton ginning machine.

What is Ginning, Ginning, Ginning of Cotton

Simply to define ginning we can say that the process is used to get the cleaned cotton by separating or removing the seeds, dust or any other foreign particles. So that better cotton can be offered for the cotton spinning mills.

Objects of Ginning

  • To make the fiber-free from seeds without gin-cut fiber.
  • To ensure the best quality of cotton and get the fair price of cotton in the market.
  • To be confident that fiber does not contain excess and unexpected seeds or any other particles.
  • To make the spinning process easier and effective

Cotton Ginning Process

  1. At first, the cotton is made to go through dryers to reduce moisture content.
  2. Then the cotton is made to go through cleaning equipment to remove foreign particles or materials.
  3. The cotton is then sent to the air conveyed to gin stands where revolving circular saws pull the lint from the saw teeth by air blasts or by rotating brushes.
  4. The cotton is compressed into 500 pounds weigh contained bales.
  5. Then the bales of cotton are shipped to the textile spinning mill for further processes.
  6. To ensure better quality the overall process is monitored by a quality control team.
ginning process of cotton
Ginning of cotton

Modern Cotton Ginning Process

In an automatic modern ginning process of cotton, a modern machine is used. Before cotton arrives at the spinning mill to spin into thread and woven into the fabric, it makes the journey from field to bale. Cotton needs about five months to grow from a planted seed to a ready plant. The harvesting machine named cotton picker plucks fluffy seed cotton out of the plant’s boll and leave a trail of burrs and sticks behind. The machine empties the pulled cotton into a tractor-drawn buggy. The machine builds the seed cotton into a humongous rectangular block called a module. A truck transports the module to the processing plant, which is known as a cotton gin. Once the cotton arrives at the processing plant, sticks and burrs are removed as well as any lingering debris and seeds. A truck dumps the module into a feeder, which moves the packed seed cotton into a dispenser. The ground seed cotton falls onto a conveyor belt, which leads to the hot box, then the hotbox mixes the seed cotton with hot air, which allows the moisture to evaporate, making the seed cotton easier to clean. A machine called the Wad Buster breaks up the clumps of seed cotton by tossing it against a screen. Loose remains fall through the screen openings down a narrow chute. Then the seed cotton moves through a machine called the steady flow, which divides it equally between two processing lines. On each line, the seed cotton enters a Burr Machine, which grabs the seed cotton with a circular saw and swings it against metal bars.

The centrifugal force shakes off the heavier debris. The seed cotton passes the machine through one pipe and the debris through another. A large auger transfers the debris to a waste drop and out of the plant. Then the seed cotton is ready for the final step of processing. A network of pipes feeds a row of machines called Gin Stands. The gin stand separates the seed from the fluffy stuff, called the lint. Inside each stand are arranged horizontally, each separated by a steel rib. The saw teeth grab the seed cotton and pull the lint through the narrow gap between saw and rib. The seeds are too large to pass through, so it spins in front of the rib, then drops into a conveyor. The lint goes into a flue, which leads to the packaging area. And then use this cotton in the spinning mill to make the thread.

Types of Cotton Ginning

There are two basic types of Ginning you may find. These are:

Saw Ginning of Cotton

Rather than manual ginning, saw ginning is used which provides more clean cotton compared with manual or handheld separation process of seed from cotton.

Advantage of Cotton Saw Ginning

  1. Saw ginned cotton is more uniform
  2. Cotton is more clean than usual.

The Disadvantage of Cotton Saw Ginning

  1. Possibility of fiber breakage due to draw up the fiber from the surface of the seed.
  2. Increase neps
  3. Increase short fiber content

Roller Ginning of Cotton

In the case of modern ginning, an automated roller is used in the ginning process of cotton. Nowadays this type of ginning technology is highly used for industrial purpose.

Advantage of Roller Ginning of Cotton

  1. Fiber quality is better compared with saw ginned cotton.
  2. High production because of the use of advanced technology in the ginning process.

The Disadvantage of Roller Ginning of Cotton

  1. The moisture of seed mixes up with fiber in processing which causes cake cotton fault.

Faults in Ginning Process of Cotton

  1. Gin-cut fiber
  2. Crushed seeds
  3. Neps formation
  4. Too much wastage

Written by
Engineer Sheikh Nurja, and
Md. Nahian Mahmud Shaikat

How to Obtain Dimensional Stability in Foil Print

Dimensional Stability in Foil Print

How to Obtain Dimensional Stability in Foil Print While Keeping the Desired Shade Within an Optimal Process for Compact Jersey fabrics.

Obtain Dimensional Stability in Foil Print
Setting Target for Obtain Dimensional Stability in Foil Print
Root Cause Analysis of Instability in Foil Print

Solution Analysis

ProblemsResource R.FeasibilitySignificanceTime-SavingTotalPriority
Fabric Structure1191128th
Chemical characteristics2282146th (2)
Cross-linking agent2282146th (1)
Improper roller passing5572194th
Improper temperature8893281st
Improper padding pressure7893272nd
Relative Humidity2361128th
Absenteeism3541137th (1)
Unskilled worker2263137th (2)
Blower pressure2341109th
Machine tension1152910th
Use of steam4381165th
Speed variation5594243rd (2)
Improper fabric feeding7791243rd (1)
Unconsciousness7131128th (3)

5W-1H Analysis (Reason 1)

QuestionImproper Temperature
Where does it happen?In  Finishing
Why it is a problem?Affects foil shade
What to do?Find out an optimal temperature
Who will do?QCC team
When will do?Within 1 month
How much it will cost?Moderate cost

Developing Solutions for Reason 1: Improper Temperature

S/LSolution suggestedAnalysisRemarks
1a) Dryer + Compacting above 100ºC b) Stenter above 100ºCShade not okNot accepted
2Dryer below 100ºCShade ok, but dimension fails in lengthwise & diameter shortNot accepted
3CompactingShade not okNot accepted
4Stenter below 100ºCa) Shade ok but dimension varies with pressure b) Shade & dimension ok; but, requires 5-6% excess process loss due to GSM problemNeed more analysis
5Tumble DryShade & dimension ok; but, requires 5-6% excess process loss due to GSM problemNeed more analysis

5W-1H Analysis (Reason 2)

QuestionImproper padding pressure
Where is happens?In Stenter machine
Why it is a problem?Affects foil
What to do?Find out an optimal pressure & avoid maximum pressure
Who will do?QCC team
When will do?Within 1 month
How much it will cost?Moderate cost

Developing Solutions for Reason 2: Improper Padding Pressure

Solution suggestedAnalysisRemarks
Stenter below 100ºC with double padderAffects foil for high pressure & causes lengthwise extension resulting dimension failureNot accepted
Stenter below 100ºC with single padder (maintaining low pressure)Shade & dimension okAccepted
QCC Team's Solution for Obtaining Dimensional Stability

Foreseeing Resistance

ResistanceAnalysis & Solution
Dimensional stability is changed after foil print due to DelaminationControl GSM, Shrinkage & Water Absorbency before printing (semi-finished while gumming & cutting)
If finished before printing, absorbency may be reduced at finishingUsed Hydrophilic Softener
This technique is not applicable to loose knitted fabricsWe will work on this in our next project

Result Analysis

Order Number: GISGM1419
Fabrication: 100% Cotton, Interlock, Diameter- 62’’, GSM-180
Order Volume: 3,130 KG
Fabric Delivered: 2912 KG

S/LParameter (after finishing)Tumble-dryNew Process
1Processed quantity1490 kg1422 kg
2Diameter57~59’’60~62’’
3GSM188~192175~182
4Consumption6.8% moreNo excess required

The final result achieved from our project

Dimensional StabilityBuyer requirement
Fabric save0.068
Foil Save0.074
Milestone Chart of Dimensional Stability of Foil Print

Written By
Sharmin Akther Diba
Industrial & Production Engineer
Rajshahi University of Engineering & Technology
Email: [email protected]
LinkedIn: Sharmin Akther Diba

Operation Breakdown, SMV and Layout of Lingerie

Operation Breakdown, SMV and Layout of Lingerie Manufacturing

Lingerie is undergarments of women which includes bra, panty. Lingerie is made based on the customer’s requirement which can be varied by color, size, and materials used. Here in this article, our focus is on panty of girls where we will show operation breakdown, SMV and layout of lingerie manufacturing. The Maximum Operator 20 person is Required, machine required is 13 unit and Total SMV is 4.52 for lingerie (panty).

Operation Breakdown, SMV and Layout of Lingerie Manufacturing

SMV of Lingerie Manufacturing

SQ NOOPERATION DESCRIPTIONM/C  TYPESMVTGT. AT 100%TMLAML
1Attach frt panel to back1 Z/Z0.829722.392.0
2Join front gusset seam4TH/OL0.2862100.821.0
3Attach lace trim to front panel x 22FL/ CB0.5651061.631.0
4Attach waist elastic circular short3FL/LA0.4821241.392.0
5Secure labels to the wrong side of waist elastic joinSNLS0.2592320.75
6Turn back waist elastic & x/st topstitch down1 Z/Z0.6031001.732.0
7Attach. Elastic to leg3FL/LA0.4701281.352.0
8Join back gusset seam3FL/ FB0.4311391.241.0
9Secure back gusset seam x 2B/T0.3931531.131.0
10Spot tack attach bow central on front waistB/A0.1993020.571.0
11Exam
12Folding & pack
TOTAL4.521313.0

Machine Summary

MACHINE TYPESHORT CODEREQUIRED QTY
4 Thread Over Lock4TH/OL1
2 Needle Flat lock Cover Seam Cylinder Bed2FL/ CB1
3 Needle Flat lock Cover Seam  Flat  Bed3FL/ FB1
3-Needle RHK Flat Lock Latch Attached Machine3FL/LA4
Button AttachB/A1
Bar TackB/T1
1 Step Zig Zag1 Z/Z4
Total13

Written by
A.M. Amirul Islam (Washim)
Email: [email protected]
Linkedin: A.M. Amirul Islam

Operation Breakdown, SMV and Layout of Shimmer Dress

Operation Breakdown, SMV and Layout of Shimmer Dress

Shimmer dress specially made for girls which are used on different occasions around the world by the models or celebrities. The shimmer gives a girl a gorgeous look. The dress is come up with different colors with a shiny outlook. Here in this article, you will have operation breakdown, SMV and layout of shimmer dress manufacturing. Total Manpower Requirement = 27 Person for garments production, Total Machine Requirement is 27 and Total SMV of shimmer dress manufacturing is 17.60.

Operation Breakdown, SMV and Layout of Shimmer Dress Manufacturing
SQ NOOPERATION DESCRIPTIONM/C  TYPESMVTMLAML
1Msr & cut tape to length & tape thru zip & l/s secureSNLS0.4420.681.0
2Attach tape to lower edge of inner collarSNLS0.6671.021.0
3Join inner & outer collar at outer edges4TH/OL0.6671.021.0
4Bluffstitch inner & outer collarSNLS0.6831.051.0
5Shoulders with / without tape4TH/OL0.6250.961.0
6Insert sleeves4TH/OL0.9201.411.5
7Mark & attach outer collar onto neck edges4TH/OL0.7501.151.0
8Mark & l/s attach frt pkt linner to frt pnl at pkt openingSNLS0.6671.022.0
9Snip, turn & l/s topstitch front pocket openings to form welt effectSNLS0.8501.301.0
10Close frt linner to bk pkt bags4TH/OL0.5000.771.5
11Secure tack pkt bags into pos at sideseamsSNLS0.7201.102.0
12Sides/sleeves long wrap inc labels4TH/OL1.5002.302.0
13Hem wrap2FL/L-C0.9171.411.0
14Mark & l/s attach zip to CF insideSNLS2.5003.842.0
15Bagout inner collar at CF neck on zipper edgeSNLS0.5000.772.0
16Neaten Centre body from collar edge to hem edge4TH/OL1.1671.791.0
17Topstitch zip into posSNLS0.6601.011.0
18Close inner collar tape seam  with loopSNLS0.7501.152.0
19Cuffs (circular) long slv dress2FL/ SCB0.8191.261.0
20iron fleece/toweling/ knitted long wrap1.1671.791.0
21Form back neck loop, msr & cut to length2FL/ CB0.1290.20
Total17.6027.027

Machine Summary of Shimmer Dress

Machine TypeShort CodeRequired QTY
Single Needle Lock StitchSNLS15
4 Thread Over Lock4TH/OL9
2 Needle Flat Lock Cover Seam Small Cylinder Bed2FL/SCB1
2 Needle Flat Lock Cover Seam Cylinder Bed2FL/CB1
2 Needle Flat Lock Cover Seam Left Side Cutter2FL/L-C1
Total27

Written by
A.M. Amirul Islam (Washim)
Email: [email protected]
Linkedin: A.M. Amirul Islam

Operation Breakdown, SMV and Layout of Ladies Overall

Operation Breakdown, SMV and Layout of Ladies Overall

In this article, you will have details of Operation Breakdown, SMV and Layout of Ladies Overall

  • Allocated ManPower = 77 Person
  • Total SMV = 32.93
  • Number of Machine = 53 Unit
SEQ NOOPERATIONM/C
Types
SMVMP
1Front pocket position markMNL0.441
2Pocket edges hem2FL/ SCY0.321
3Pre iron pocket edgesIRON0.701
4Pocket attachSNLS1.202
5Pocket extra raw edges cutMNL0.501
6Back pocket & flap position markMNL0.521
7Fusing attach at pocket edgeIRON0.201
8Pocket edges hem2FL/ SCY0.301
9Pocket pressIRON0.701
10Pocket attach at back partSNLS1.202
11Pocket extra raw edges cutMNL0.501
12Fusing attach at flapIRON0.241
13Flap makeSNLS0.801
14Pocket flap edge cut & turn with pressIRON0.401
15Flap 1/16 topstitchSNLS0.801
16Flap 1/4 topstitchSNLS0.751
17Flap attach n topstitchSNLS0.882
18Rise join keeping front rise upto cutmark open4TH/OL0.651
19Front rise upper tackSNLS0.181
20Front & back part matchMNL0.281
21Side markMNL0.301
22Care label makeSNLS0.241
23Side seam join inserting care label4TH/OL0.801
24Sleeve mark for tape attachMNL0.441
25Sleeve tape attach & cutFOA0.882
26Sleeve & body sticker matchMNL0.351
27Insert raglan sleeve to body4TH/OL1.102
28Body mark to cutMNL0.181
29Body cutMNL0.201
30Collar fold & edge tackSNLS0.281
31Collar edge close & markSNCS0.301
32Collar tack to bodySNLS0.281
33Collar attach to body4TH/OL0.301
34Neck topstitch1FL/ CY0.421
35Zipper runner secure tack & zipper edge fold tackSNLS0.401
36Zipper edge binding & cut1FL/BIN0.561
37Binding edges tack & cutSNLS0.321
38Side seam join4TH/OL0.421
39Mark & make holeB/H0.361
40Tie cut to lengthMNL0.201
41Tie edge fold & tackSNLS0.361
42Tie edge secure to holeSNLS0.401
43Elastic press & cut to length *3IRON0.361
44Elastic sandwich tackSNLS0.401
45Elastic attach at both side of waist tunnel3TH O/L0.601
46Top & bottom part matchMNL0.281
47Tunnel part attach4TH/OL0.902
48Zipper n body markMNL0.351
49Mark & fistail cutMNL0.301
50Zipper tackSNLS0.281
51Zipper attachSNLS1.002
52Zipper base neaten4TH/OL0.161
53Zipper base secureSNLS0.181
54Elastic join as a circleDNLS0.301
55Cuff join as a circleSNLS0.301
56Elastic attach to cuff3TH O/L0.401
57Cuff fold & tackSNLS0.401
58Cuff edge close & markSNCS0.451
59Cuff attach at leg4TH/OL0.501
60Sticker remove & gmt turnMNL0.351
61Sleeve edge neaten3TH O/L0.421
62Sleeve hem1FL/ CY0.501
63Zipper topstitchSNLS1.102
64Label position markMNL0.161
65Label attachSNLS0.301
66Button position markMNL0.441
67Button attach to pocket & flapB/A1.202
68Thread trim, Zipper & button closeMNL0.651
Total32.9377
Operation Breakdown, SMV and Layout of Ladies Overall

Machine Summary of Ladies Overall

CodeMachine nameQuantity
SNLSSingle Needle Lock Stitch27
SNCSSingle Needle Chain Stitch2
DNLSDouble Needle Lock Stitch1
3TH O/L3 Thread Over Lock3
4TH/OL4 Thread Over Lock10
2FL/ SCY2 Needle Flat lock Small  Cylinder Bed2
1FL/ CY1 Needle Flat lock Cylinder Bed2
1FL/BIN1 Needle Flat lock Binding Machine1
B/AButton Attach2
B/HButton Hole1
FOAFeed Of The Arm2
Total No of Machines53

Manpower Summary of Ladies Overall

MNLManual (Helper)18
IRONIron With Table6
Total No of Manpower77

Written By
Sharmin Akther Diba
Industrial & Production Engineer
Rajshahi University of Engineering & Technology
Email: [email protected]
LinkedIn: Sharmin Akther Diba

Operation Breakdown, SMV and Layout of Kids Overall Hoodie

Operation Breakdown, SMV and Layout of Kids Overall Hoodie

In this article, you will have details of Operation Breakdown sheet, SMV and Layout of Kids Overall Hoodie.

  • Allocated ManPower = 77 Person
  • Total SMV = 21.60
  • Number of Machine = 59 Unit
Seq. NoBody PartOperationResourceSMVLayout MP
1LabelCare Label makeSNL Auto0.241
2PocketingPocket position markAssistant Operator0.241
3PocketingPocket hem2NDL FL0.281
4LabelPatch label position markAssistant Operator0.161
5LabelPatch label attach at pocketSNL Auto0.361
6PocketingPre Iron pocket [email protected]Sewing Iron0.351
7PocketingPocket attach and edge close-[Kangaroo]SNL Auto0.602
8PocketingPocket excess raw-edge cutAssistant Operator0.301
9SleeveSleeve n Body matchAssistant Operator0.351
10SleeveSleeve attach4T OL Auto0.602
11HoodHood upper three part join4T OL Auto0.502
12HoodHood linner two part join4T OL Auto0.261
13HoodHood upper n liner opening join4T OL Auto0.301
14HoodBluffstitch hood join seam1NDL FL0.371
15HoodHood channel make1NDL FL0.401
16HoodBridge cut n hood middle tack with linkingSNL Auto0.301
17HoodHood lower edge closeSNL[Chain STS]0.301
18Front PartBody markAssistant Operator0.241
19Front PartCut C/frt and form fishtailAssistant Operator0.261
20PlacketFusing attach at placket n half foldSewing Iron0.251
21PlacketPlacket edge rollingSNL Auto0.301
22PlacketPlacket Draw with templateAssistant Operator0.201
23PlacketPlacket attachSNL Auto0.482
24PlacketPlacket 1/16 top stichSNL Auto0.221
25HoodHood n body match n markAssistant Operator0.301
26HoodHood tack at neckSNL Auto0.281
27HoodHood attach4T OL Auto0.351
28PlacketPlacket nose tack with hoodSNL Auto0.482
29NeckNeck tape attach n trimSNL Auto0.381
30PlacketPlacket closeSNL Auto0.241
31LabelLabel position markAssistant Operator0.161
32NeckNeck top stitch insert labelSNL Auto0.482
33PlacketSecure fishtailSNL Auto0.241
34PlacketPlacket box make with cross tackSNL Auto0.442
35AssemblySide/ sleeve seam insert care label, placket base o/l4T OL Auto0.622
36CuffCuff join as a circle x2SNDL Edg Cutter0.281
37CuffCuff fold into halfAssistant Operator0.241
38CuffCuff attach at sleeve opening4T OL Auto0.452
39AssemblyGusset attach at back part4T OL Auto0.301
40CuffCuff attach at leg opening4T OL Auto0.452
41PlacketFusing attach at placketSewing Iron0.321
42PlacketPlacket make LowerSNL Auto0.602
43PlacketPlacket make upperSNL Auto0.602
44PlacketPlacket turn n edge closeSNL Auto1.003
45PlacketPlacket inner/lower edge tackSNL Auto0.482
46PlacketPlacket attach4T OL Auto0.702
47PlacketPlacket topstitchSNL Auto0.883
48PlacketSecure placket baseSNL Auto0.181
49AssemblySticker remove and GMTs turnAssistant Operator0.251
50PlacketButton position mark X7Assistant Operator0.321
51PlacketButton attach x7 + 1 spareSnap BA0.963
52PlacketButton position markAssistant Operator0.321
53PlacketButton attach x7Snap BA0.843
54AssemblyThread trim n button closeAssistant Operator0.602
Total21.6077
Operation Breakdown, SMV and Layout of Kids Overall Hoodie

SMV Summary of Kids Overall Hoodie

Sewing Helper4.86
Sewing Machine16.74
Sewing QI0.00
Finishing I/M0.00
Finishing QI0.00
Poly Helper0.00
Packing0.00
Hand Tag0.00
Total21.60

Manpower Summary of Kids Overall Hoodie

Sewing Helper18
Sewing Machine59
Sewing QI0
Finishing I/M0.00
Finishing QI0
Poly Helper0
Packing0
Hand Tag0
Total77

Machine Summary of Kids Overall Hoodie

SNL Auto32
2NDL FL1
4T OL Auto16
1NDL FL2
SNL[Chain STS]1
SNDL Edg Cutter1
Snap BA6
Total59

Written By
Sharmin Akther Diba
Industrial & Production Engineer
Rajshahi University of Engineering & Technology
Email: [email protected]
LinkedIn: Sharmin Akther Diba

Operation Breakdown, SMV and Layout of Brooke Short Pant

Operation Breakdown, SMV and Layout of Brooke Short Pant

  • Efficiency = 49%
  • Total SMV = 9.32
  • Total Manpower Required = 32
  • Total Number of Machine Required = 27
Brooke Short Pant
Seq. NoBody PartOperationResourceSMVLayout MP
1Front PartFront rise join4T OL Auto0.261
2Back PartBack rise join4T OL Auto0.301
3AssemblyLeft n right leg matchSewing Helper0.261
4AssemblyInseam join4T OL Auto0.181
5AssemblyPannel edge neatenOL Cutter0.361
6AssemblySide pannel attach4T OL Auto0.803
7AssemblyBinding at one side to another around n trimFlat Bed1.103
8AssemblyMark and side seam topstitchSNL Auto1.203
9AssemblySecure Crotch pointBT0.161
10Waist BeltElastic press,measure & cutSewing Iron0.201
11Waist BeltWaistband join as a circle n markSNDL Edge Cutter0.301
12Waist BeltElastic join as a circle & markDNL Lock Switch Auto0.301
13Waist BeltMark n form hole at waistbandBH Auto0.351
14Waist BeltSandwich elastic with waistband & tackSNL Auto0.401
15Waist BeltWaistband topstitch form channelKNS0.502
16Waist BeltWaist Band lower edges close & MarkSNL[Chain STS]0.452
17Waist BeltAttach waistband to the body4T OL Auto0.502
18LabelCare label makeSNL Auto0.241
19LabelLabel attach at WBSNL Auto0.351
20AssemblySticker remove & GMTs turnSewing Helper0.261
21AssemblyDrawsting insert through the waist channelSewing Helper0.301
22AssemblyDrawsting secure at CB waistbandBT0.181
23AssemblyThread trimsSewing Helper0.351
Total9.3032
Operation Breakdown, SMV and Layout of Brooke Short Pant

SMV Summary of Brooke Short Pant

Sewing Helper1.37
Sewing Machine7.93
Sewing QI0.00
Finishing I/M0.00
Finishing QI0.00
Poly Helper0.00
Packing0.00
Total9.30

Machine Summary of Brooke Short Pant

4T OL Auto8
OL Cutter1
Flat Bed3
SNL Auto6
BT2
SNDL Edge Cutter1
DNL Lock Switch Auto1
BH Auto1
KNS2
SNL[Chain STS]2
Total27

Man Power SUmmary of Brooke Short Pant

Sewing Helper5
Sewing Machine27
Sewing QI0
Finishing I/M0.00
Finishing QI0
Poly Helper0
Packing0
Hand Tag0
Total32

Written By
Sharmin Akther Diba
Industrial & Production Engineer
Rajshahi University of Engineering & Technology
Email: [email protected]
LinkedIn: Sharmin Akther Diba

Operation Breakdown, SMV and Layout of Brooke Skirt

Operation Breakdown, SMV and Layout of Brooke Skirt

  • Efficiency = 42%
  • Total SMV = 7.9
  • Total Manpower Requried = 28
  • Total Number of Machine Required = 23
Brooke Skirt
Seq. NoBody PartOperationResourceSMVTarget (100%)Layout MP
1Front PartBottom binding n trimsFlat Bed0.331821
2AssemblyFront n back part matchAssistant Operator0.262311
3AssemblySide seam4T OL Auto0.451332
4AssemblyBinding at one side to another around n trimFlat Bed0.90673
5AssemblyMark and side seam topstitchSNL Auto1.00603
6Waist BeltElastic press,measure & cutSewing Iron0.203001
7Waist BeltWaistband join as a circle n markSNDL Edge Cutter0.302001
8Waist BeltElastic join as a circle & markDNL Lock Switch Auto0.302001
9Waist BeltMark n form hole at waistbandSnap0.282141
10AssemblyEyelet attachSnap BA0.351711
11Waist BeltSandwich elastic with waistband & tackSNL Auto0.401501
12Waist BeltWaistband topstitch form channelKNS0.501202
13Waist BeltWaist Band lower edges close & MarkSNL [Chain STS]0.451332
14Waist BeltAttach waistband to the body4T OL Auto0.501202
15LabelCare label makeSNL Auto0.242501
16LabelLabel attach at WBSNL Auto0.351711
17AssemblySticker remove & GMTs turnAssistant Operator0.262311
18AssemblyDrawsting insert through the waist channelAssistant Operator0.302001
19AssemblyDrawsting secure at CB waistbandBT0.183331
20AssemblyThread trimsAssistant Operator0.351711
Total7.9028
Operation Breakdown, SMV and Layout of Brooke Skirt

SMV Summary of Brooke Skirt

Sewing Helper1.37
Sewing Machine6.53
Sewing QI0.00
Finishing I/M0.00
Finishing QI0.00
Poly Helper0.00
Packing0.00
Hand Tag0.00
Total7.90

Man Power Summary of Brooke Skirt

Sewing Helper5
Sewing Machine23
Sewing QI0
Finishing I/M0.00
Finishing QI0
Poly Helper0
Packing0
Hand Tag0
Total28

Machine Summary of Brooke Skirt

Flat Bed4
4T OL Auto4
SNL Auto6
SNDL Edg Cutter1
DNL Lock Switch Auto1
Snap1
Snap BA1
KNS2
SNL[Chain STS]2
BT1
Total23

Written By
Sharmin Akther Diba
Industrial & Production Engineer
Rajshahi University of Engineering & Technology
Email: [email protected]
LinkedIn: Sharmin Akther Diba

Operation Breakdown, SMV and Layout of Brooke Hoodies

Operation Breakdown, SMV and Layout of Brooke Hoodies

  • Total SMV = 15.66
  • Total Manpower Requried = 56
  • Total Number of Machine Required = 45
Brooke Hoodies
Seq. NoBody PartOperationResourceSMVLayout MP
1AssemblyFront n back part matchAssistant Operator0.261
2AssemblyShoulder Join with/ without tape4T OL Auto0.361
3HoodHood two part join4T OL Auto0.321
4HoodHood band attach at hood openingFlat Bed0.351
5HoodHood edge neatenOL Cutter0.261
6HoodHood edges tack as circleSNL Auto0.241
7HoodHood n body markAssistant Operator0.301
8HoodHood tack at neckSNL Auto0.261
9HoodHood attach to body4T OL Auto0.351
10NeckBack neck bindingFlat Bed0.301
11NeckBinding edges tack n cutSNL Auto0.361
12LabelLabel position markAssistant Operator0.161
13NeckBack neck top stitch insert labelSNL Auto0.401
14SleeveSleeve n body matchAssistant Operator0.351
15SleeveInsert Sleeves4T OL Auto0.562
16LabelCare Label MakeSNL Auto0.241
17AssemblySide/ sleeve seam insert care label4T OL Auto0.702
18CuffCuff join as a circleX2SNL Auto0.281
19CuffCuffs fold in half and markAssistant Operator0.241
20CuffCuff attach at sleeve opening4T OL Auto0.502
21AssemblyBottom binding n trimsFlat Bed0.502
22AssemblyFront n back part matchAssistant Operator0.261
23AssemblySide seam4T OL Auto0.452
24AssemblyBinding at one side to another around n trimFlat Bed0.903
25AssemblyMark and side seam topstitchSNL Auto1.004
26Waist BeltElastic press,measure & cutSewing Iron0.201
27Waist BeltWaist band join as a circle n markSNDL Edg Cutter0.301
28Waist BeltElastic join as a circle & markDNL Lock Switch Auto0.301
29Waist BeltMark n make hole for eyeletSnap0.281
30Waist BeltEyelet attachSnap BA0.351
31Waist BeltSandwich elastic with waist band & tackSNL Auto0.401
32Waist BeltWaist band fold run stitchSNL[Chain STS]0.321
33Waist BeltWaist band lower edge close n markSNL[Chain STS]0.452
34Waist BeltAttach waist band to body4T OL Auto0.502
35AssemblyTop n bottom part matchAssistant Operator0.281
36AssemblyTop n bottom part tackSNL Auto0.301
37AssemblyTop n Bottom attach together4T OL Auto0.502
38AssemblySticker remove and GMTs turnAssistant Operator0.251
39CuffCuff top-stitch2NDL FL0.502
40AssemblyDrawsting insert through the waist channelAssistant Operator0.301
41AssemblyDrawsting secure at CB waist bandBT0.181
42AssemblyThread trimsAssistant Operator0.351
Total15.6656
Operation Breakdown, SMV and Layout of Brooke Hoodies

SMV Summary of Brooke Hoodies

Sewing Helper2.95
Sewing Machine12.71
Sewing QI0.00
Finishing I/M0.00
Finishing QI0.00
Poly Helper0.00
Packing0.00
Hand Tag0.00
Total15.66

Man Power Summary of Brooke Hoodies

Sewing Helper11
Sewing Machine45
Sewing QI0
Finishing I/M0.00
Finishing QI0
Poly Helper0
Packing0
Hand Tag0
Total56

Machine Summary of Brooke Hoodies

4T OL Auto15
Flat Bed7
OL Cutter1
SNL Auto12
SNDL Edg Cutter1
DNL Lock Switch Auto1
Snap1
Snap BA1
SNL[Chain STS]3
2NDL FL2
BT1
Total45

Written By
Sharmin Akther Diba
Industrial & Production Engineer
Rajshahi University of Engineering & Technology
Email: [email protected]
LinkedIn: Sharmin Akther Diba