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Break Even Analysis of Apparel Industry

By Nahian Mahmud Shaikat August 19, 2019 August 19, 2019 Apparel, Textile Calculation

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:

Sales Price Per Unit
Total Sales Quantity/ Expected Sales Quantity
Variable Cost Per Unit
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

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

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

Break Even (Quantity): 847,458 Piece
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

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Ginning: Cotton Ginning, Process, Types, and Objectives

By Nahian Mahmud Shaikat August 17, 2019 August 23, 2019 Introduction To Spinning, Spinning

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

At first, the cotton is made to go through dryers to reduce moisture content.
Then the cotton is made to go through cleaning equipment to remove foreign particles or materials.
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.
The cotton is compressed into 500 pounds weigh contained bales.
Then the bales of cotton are shipped to the textile spinning mill for further processes.
To ensure better quality the overall process is monitored by a quality control team.

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
Roller Ginning

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

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

The Disadvantage of Cotton Saw Ginning

Possibility of fiber breakage due to draw up the fiber from the surface of the seed.
Increase neps
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

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

The Disadvantage of Roller Ginning of Cotton

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

Faults in Ginning Process of Cotton

Gin-cut fiber
Crushed seeds
Neps formation
Too much wastage

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

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How to Obtain Dimensional Stability in Foil Print

By Nahian Mahmud Shaikat August 7, 2019 August 7, 2019 Apparel

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.

Setting Target for Obtain Dimensional Stability in Foil Print

Root Cause Analysis of Instability in Foil Print

Solution Analysis

Problems	Resource R.	Feasibility	Significance	Time-Saving	Total	Priority
Fabric Structure	1	1	9	1	12	8th
Chemical characteristics	2	2	8	2	14	6th (2)
Cross-linking agent	2	2	8	2	14	6th (1)
Improper roller passing	5	5	7	2	19	4th
Improper temperature	8	8	9	3	28	1st
Improper padding pressure	7	8	9	3	27	2nd
Relative Humidity	2	3	6	1	12	8th
Absenteeism	3	5	4	1	13	7th (1)
Unskilled worker	2	2	6	3	13	7th (2)
Blower pressure	2	3	4	1	10	9th
Machine tension	1	1	5	2	9	10th
Use of steam	4	3	8	1	16	5th
Speed variation	5	5	9	4	24	3rd (2)
Improper fabric feeding	7	7	9	1	24	3rd (1)
Unconsciousness	7	1	3	1	12	8th (3)

5W-1H Analysis (Reason 1)

Question	Improper 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/L	Solution suggested	Analysis	Remarks
1	a) Dryer + Compacting above 100ºC b) Stenter above 100ºC	Shade not ok	Not accepted
2	Dryer below 100ºC	Shade ok, but dimension fails in lengthwise & diameter short	Not accepted
3	Compacting	Shade not ok	Not accepted
4	Stenter below 100ºC	a) Shade ok but dimension varies with pressure b) Shade & dimension ok; but, requires 5-6% excess process loss due to GSM problem	Need more analysis
5	Tumble Dry	Shade & dimension ok; but, requires 5-6% excess process loss due to GSM problem	Need more analysis

5W-1H Analysis (Reason 2)

Question	Improper 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 suggested	Analysis	Remarks
Stenter below 100ºC with double padder	Affects foil for high pressure & causes lengthwise extension resulting dimension failure	Not accepted
Stenter below 100ºC with single padder (maintaining low pressure)	Shade & dimension ok	Accepted

QCC Team's Solution for Obtaining Dimensional Stability

Foreseeing Resistance

Resistance	Analysis & Solution
Dimensional stability is changed after foil print due to Delamination	Control GSM, Shrinkage & Water Absorbency before printing (semi-finished while gumming & cutting)
If finished before printing, absorbency may be reduced at finishing	Used Hydrophilic Softener
This technique is not applicable to loose knitted fabrics	We 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/L	Parameter (after finishing)	Tumble-dry	New Process
1	Processed quantity	1490 kg	1422 kg
2	Diameter	57~59’’	60~62’’
3	GSM	188~192	175~182
4	Consumption	6.8% more	No excess required

The final result achieved from our project

Dimensional Stability	Buyer requirement
Fabric save	0.068
Foil Save	0.074

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

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Operation Breakdown, SMV and Layout of Lingerie

By Nahian Mahmud Shaikat August 7, 2019 August 7, 2019 Apparel, Industrial Engineering (IE)

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).

SMV of Lingerie Manufacturing

SQ NO	OPERATION DESCRIPTION	M/C TYPE	SMV	TGT. AT 100%	TML	AML
1	Attach frt panel to back	1 Z/Z	0.829	72	2.39	2.0
2	Join front gusset seam	4TH/OL	0.286	210	0.82	1.0
3	Attach lace trim to front panel x 2	2FL/ CB	0.565	106	1.63	1.0
4	Attach waist elastic circular short	3FL/LA	0.482	124	1.39	2.0
5	Secure labels to the wrong side of waist elastic join	SNLS	0.259	232	0.75
6	Turn back waist elastic & x/st topstitch down	1 Z/Z	0.603	100	1.73	2.0
7	Attach. Elastic to leg	3FL/LA	0.470	128	1.35	2.0
8	Join back gusset seam	3FL/ FB	0.431	139	1.24	1.0
9	Secure back gusset seam x 2	B/T	0.393	153	1.13	1.0
10	Spot tack attach bow central on front waist	B/A	0.199	302	0.57	1.0
11	Exam	–	–	–	–	–
12	Folding & pack	–	–	–	–	–
–	TOTAL	–	4.52	–	13	13.0

Machine Summary

MACHINE TYPE	SHORT CODE	REQUIRED QTY
4 Thread Over Lock	4TH/OL	1
2 Needle Flat lock Cover Seam Cylinder Bed	2FL/ CB	1
3 Needle Flat lock Cover Seam Flat Bed	3FL/ FB	1
3-Needle RHK Flat Lock Latch Attached Machine	3FL/LA	4
Button Attach	B/A	1
Bar Tack	B/T	1
1 Step Zig Zag	1 Z/Z	4
Total	–	13

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

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Operation Breakdown, SMV and Layout of Shimmer Dress

By Nahian Mahmud Shaikat August 7, 2019 August 7, 2019 Apparel, Industrial Engineering (IE)

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.

SQ NO	OPERATION DESCRIPTION	M/C TYPE	SMV	TML	AML
1	Msr & cut tape to length & tape thru zip & l/s secure	SNLS	0.442	0.68	1.0
2	Attach tape to lower edge of inner collar	SNLS	0.667	1.02	1.0
3	Join inner & outer collar at outer edges	4TH/OL	0.667	1.02	1.0
4	Bluffstitch inner & outer collar	SNLS	0.683	1.05	1.0
5	Shoulders with / without tape	4TH/OL	0.625	0.96	1.0
6	Insert sleeves	4TH/OL	0.920	1.41	1.5
7	Mark & attach outer collar onto neck edges	4TH/OL	0.750	1.15	1.0
8	Mark & l/s attach frt pkt linner to frt pnl at pkt opening	SNLS	0.667	1.02	2.0
9	Snip, turn & l/s topstitch front pocket openings to form welt effect	SNLS	0.850	1.30	1.0
10	Close frt linner to bk pkt bags	4TH/OL	0.500	0.77	1.5
11	Secure tack pkt bags into pos at sideseams	SNLS	0.720	1.10	2.0
12	Sides/sleeves long wrap inc labels	4TH/OL	1.500	2.30	2.0
13	Hem wrap	2FL/L-C	0.917	1.41	1.0
14	Mark & l/s attach zip to CF inside	SNLS	2.500	3.84	2.0
15	Bagout inner collar at CF neck on zipper edge	SNLS	0.500	0.77	2.0
16	Neaten Centre body from collar edge to hem edge	4TH/OL	1.167	1.79	1.0
17	Topstitch zip into pos	SNLS	0.660	1.01	1.0
18	Close inner collar tape seam with loop	SNLS	0.750	1.15	2.0
19	Cuffs (circular) long slv dress	2FL/ SCB	0.819	1.26	1.0
20	iron fleece/toweling/ knitted long wrap	–	1.167	1.79	1.0
21	Form back neck loop, msr & cut to length	2FL/ CB	0.129	0.20	–
–	Total	–	17.60	27.0	27

Machine Summary of Shimmer Dress

Machine Type	Short Code	Required QTY
Single Needle Lock Stitch	SNLS	15
4 Thread Over Lock	4TH/OL	9
2 Needle Flat Lock Cover Seam Small Cylinder Bed	2FL/SCB	1
2 Needle Flat Lock Cover Seam Cylinder Bed	2FL/CB	1
2 Needle Flat Lock Cover Seam Left Side Cutter	2FL/L-C	1
Total	–	27

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

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Operation Breakdown, SMV and Layout of Ladies Overall

By Nahian Mahmud Shaikat July 31, 2019 July 31, 2019 Apparel, Industrial Engineering (IE)

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 NO	OPERATION	M/C Types	SMV	MP
1	Front pocket position mark	MNL	0.44	1
2	Pocket edges hem	2FL/ SCY	0.32	1
3	Pre iron pocket edges	IRON	0.70	1
4	Pocket attach	SNLS	1.20	2
5	Pocket extra raw edges cut	MNL	0.50	1
6	Back pocket & flap position mark	MNL	0.52	1
7	Fusing attach at pocket edge	IRON	0.20	1
8	Pocket edges hem	2FL/ SCY	0.30	1
9	Pocket press	IRON	0.70	1
10	Pocket attach at back part	SNLS	1.20	2
11	Pocket extra raw edges cut	MNL	0.50	1
12	Fusing attach at flap	IRON	0.24	1
13	Flap make	SNLS	0.80	1
14	Pocket flap edge cut & turn with press	IRON	0.40	1
15	Flap 1/16 topstitch	SNLS	0.80	1
16	Flap 1/4 topstitch	SNLS	0.75	1
17	Flap attach n topstitch	SNLS	0.88	2
18	Rise join keeping front rise upto cutmark open	4TH/OL	0.65	1
19	Front rise upper tack	SNLS	0.18	1
20	Front & back part match	MNL	0.28	1
21	Side mark	MNL	0.30	1
22	Care label make	SNLS	0.24	1
23	Side seam join inserting care label	4TH/OL	0.80	1
24	Sleeve mark for tape attach	MNL	0.44	1
25	Sleeve tape attach & cut	FOA	0.88	2
26	Sleeve & body sticker match	MNL	0.35	1
27	Insert raglan sleeve to body	4TH/OL	1.10	2
28	Body mark to cut	MNL	0.18	1
29	Body cut	MNL	0.20	1
30	Collar fold & edge tack	SNLS	0.28	1
31	Collar edge close & mark	SNCS	0.30	1
32	Collar tack to body	SNLS	0.28	1
33	Collar attach to body	4TH/OL	0.30	1
34	Neck topstitch	1FL/ CY	0.42	1
35	Zipper runner secure tack & zipper edge fold tack	SNLS	0.40	1
36	Zipper edge binding & cut	1FL/BIN	0.56	1
37	Binding edges tack & cut	SNLS	0.32	1
38	Side seam join	4TH/OL	0.42	1
39	Mark & make hole	B/H	0.36	1
40	Tie cut to length	MNL	0.20	1
41	Tie edge fold & tack	SNLS	0.36	1
42	Tie edge secure to hole	SNLS	0.40	1
43	Elastic press & cut to length *3	IRON	0.36	1
44	Elastic sandwich tack	SNLS	0.40	1
45	Elastic attach at both side of waist tunnel	3TH O/L	0.60	1
46	Top & bottom part match	MNL	0.28	1
47	Tunnel part attach	4TH/OL	0.90	2
48	Zipper n body mark	MNL	0.35	1
49	Mark & fistail cut	MNL	0.30	1
50	Zipper tack	SNLS	0.28	1
51	Zipper attach	SNLS	1.00	2
52	Zipper base neaten	4TH/OL	0.16	1
53	Zipper base secure	SNLS	0.18	1
54	Elastic join as a circle	DNLS	0.30	1
55	Cuff join as a circle	SNLS	0.30	1
56	Elastic attach to cuff	3TH O/L	0.40	1
57	Cuff fold & tack	SNLS	0.40	1
58	Cuff edge close & mark	SNCS	0.45	1
59	Cuff attach at leg	4TH/OL	0.50	1
60	Sticker remove & gmt turn	MNL	0.35	1
61	Sleeve edge neaten	3TH O/L	0.42	1
62	Sleeve hem	1FL/ CY	0.50	1
63	Zipper topstitch	SNLS	1.10	2
64	Label position mark	MNL	0.16	1
65	Label attach	SNLS	0.30	1
66	Button position mark	MNL	0.44	1
67	Button attach to pocket & flap	B/A	1.20	2
68	Thread trim, Zipper & button close	MNL	0.65	1
–	Total	–	32.93	77

Operation Breakdown, SMV and Layout of Ladies Overall

Machine Summary of Ladies Overall

Code	Machine name	Quantity
SNLS	Single Needle Lock Stitch	27
SNCS	Single Needle Chain Stitch	2
DNLS	Double Needle Lock Stitch	1
3TH O/L	3 Thread Over Lock	3
4TH/OL	4 Thread Over Lock	10
2FL/ SCY	2 Needle Flat lock Small Cylinder Bed	2
1FL/ CY	1 Needle Flat lock Cylinder Bed	2
1FL/BIN	1 Needle Flat lock Binding Machine	1
B/A	Button Attach	2
B/H	Button Hole	1
FOA	Feed Of The Arm	2
–	Total No of Machines	53

Manpower Summary of Ladies Overall

MNL	Manual (Helper)	18
IRON	Iron With Table	6
–	Total No of Manpower	77

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

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Operation Breakdown, SMV and Layout of Kids Overall Hoodie

By Nahian Mahmud Shaikat July 31, 2019 July 31, 2019 Apparel, Industrial Engineering (IE)

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. No	Body Part	Operation	Resource	SMV	Layout MP
1	Label	Care Label make	SNL Auto	0.24	1
2	Pocketing	Pocket position mark	Assistant Operator	0.24	1
3	Pocketing	Pocket hem	2NDL FL	0.28	1
4	Label	Patch label position mark	Assistant Operator	0.16	1
5	Label	Patch label attach at pocket	SNL Auto	0.36	1
6	Pocketing	Pre Iron pocket [email protected]	Sewing Iron	0.35	1
7	Pocketing	Pocket attach and edge close-[Kangaroo]	SNL Auto	0.60	2
8	Pocketing	Pocket excess raw-edge cut	Assistant Operator	0.30	1
9	Sleeve	Sleeve n Body match	Assistant Operator	0.35	1
10	Sleeve	Sleeve attach	4T OL Auto	0.60	2
11	Hood	Hood upper three part join	4T OL Auto	0.50	2
12	Hood	Hood linner two part join	4T OL Auto	0.26	1
13	Hood	Hood upper n liner opening join	4T OL Auto	0.30	1
14	Hood	Bluffstitch hood join seam	1NDL FL	0.37	1
15	Hood	Hood channel make	1NDL FL	0.40	1
16	Hood	Bridge cut n hood middle tack with linking	SNL Auto	0.30	1
17	Hood	Hood lower edge close	SNL[Chain STS]	0.30	1
18	Front Part	Body mark	Assistant Operator	0.24	1
19	Front Part	Cut C/frt and form fishtail	Assistant Operator	0.26	1
20	Placket	Fusing attach at placket n half fold	Sewing Iron	0.25	1
21	Placket	Placket edge rolling	SNL Auto	0.30	1
22	Placket	Placket Draw with template	Assistant Operator	0.20	1
23	Placket	Placket attach	SNL Auto	0.48	2
24	Placket	Placket 1/16 top stich	SNL Auto	0.22	1
25	Hood	Hood n body match n mark	Assistant Operator	0.30	1
26	Hood	Hood tack at neck	SNL Auto	0.28	1
27	Hood	Hood attach	4T OL Auto	0.35	1
28	Placket	Placket nose tack with hood	SNL Auto	0.48	2
29	Neck	Neck tape attach n trim	SNL Auto	0.38	1
30	Placket	Placket close	SNL Auto	0.24	1
31	Label	Label position mark	Assistant Operator	0.16	1
32	Neck	Neck top stitch insert label	SNL Auto	0.48	2
33	Placket	Secure fishtail	SNL Auto	0.24	1
34	Placket	Placket box make with cross tack	SNL Auto	0.44	2
35	Assembly	Side/ sleeve seam insert care label, placket base o/l	4T OL Auto	0.62	2
36	Cuff	Cuff join as a circle x2	SNDL Edg Cutter	0.28	1
37	Cuff	Cuff fold into half	Assistant Operator	0.24	1
38	Cuff	Cuff attach at sleeve opening	4T OL Auto	0.45	2
39	Assembly	Gusset attach at back part	4T OL Auto	0.30	1
40	Cuff	Cuff attach at leg opening	4T OL Auto	0.45	2
41	Placket	Fusing attach at placket	Sewing Iron	0.32	1
42	Placket	Placket make Lower	SNL Auto	0.60	2
43	Placket	Placket make upper	SNL Auto	0.60	2
44	Placket	Placket turn n edge close	SNL Auto	1.00	3
45	Placket	Placket inner/lower edge tack	SNL Auto	0.48	2
46	Placket	Placket attach	4T OL Auto	0.70	2
47	Placket	Placket topstitch	SNL Auto	0.88	3
48	Placket	Secure placket base	SNL Auto	0.18	1
49	Assembly	Sticker remove and GMTs turn	Assistant Operator	0.25	1
50	Placket	Button position mark X7	Assistant Operator	0.32	1
51	Placket	Button attach x7 + 1 spare	Snap BA	0.96	3
52	Placket	Button position mark	Assistant Operator	0.32	1
53	Placket	Button attach x7	Snap BA	0.84	3
54	Assembly	Thread trim n button close	Assistant Operator	0.60	2
–	–	–	Total	21.60	77

Operation Breakdown, SMV and Layout of Kids Overall Hoodie

SMV Summary of Kids Overall Hoodie

Sewing Helper	4.86
Sewing Machine	16.74
Sewing QI	0.00
Finishing I/M	0.00
Finishing QI	0.00
Poly Helper	0.00
Packing	0.00
Hand Tag	0.00
Total	21.60

Manpower Summary of Kids Overall Hoodie

Sewing Helper	18
Sewing Machine	59
Sewing QI	0
Finishing I/M	0.00
Finishing QI	0
Poly Helper	0
Packing	0
Hand Tag	0
Total	77

Machine Summary of Kids Overall Hoodie

SNL Auto	32
2NDL FL	1
4T OL Auto	16
1NDL FL	2
SNL[Chain STS]	1
SNDL Edg Cutter	1
Snap BA	6
Total	59

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

No comments

Operation Breakdown, SMV and Layout of Brooke Short Pant

By Nahian Mahmud Shaikat July 30, 2019 July 30, 2019 Apparel, Industrial Engineering (IE)

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

Seq. No	Body Part	Operation	Resource	SMV	Layout MP
1	Front Part	Front rise join	4T OL Auto	0.26	1
2	Back Part	Back rise join	4T OL Auto	0.30	1
3	Assembly	Left n right leg match	Sewing Helper	0.26	1
4	Assembly	Inseam join	4T OL Auto	0.18	1
5	Assembly	Pannel edge neaten	OL Cutter	0.36	1
6	Assembly	Side pannel attach	4T OL Auto	0.80	3
7	Assembly	Binding at one side to another around n trim	Flat Bed	1.10	3
8	Assembly	Mark and side seam topstitch	SNL Auto	1.20	3
9	Assembly	Secure Crotch point	BT	0.16	1
10	Waist Belt	Elastic press,measure & cut	Sewing Iron	0.20	1
11	Waist Belt	Waistband join as a circle n mark	SNDL Edge Cutter	0.30	1
12	Waist Belt	Elastic join as a circle & mark	DNL Lock Switch Auto	0.30	1
13	Waist Belt	Mark n form hole at waistband	BH Auto	0.35	1
14	Waist Belt	Sandwich elastic with waistband & tack	SNL Auto	0.40	1
15	Waist Belt	Waistband topstitch form channel	KNS	0.50	2
16	Waist Belt	Waist Band lower edges close & Mark	SNL[Chain STS]	0.45	2
17	Waist Belt	Attach waistband to the body	4T OL Auto	0.50	2
18	Label	Care label make	SNL Auto	0.24	1
19	Label	Label attach at WB	SNL Auto	0.35	1
20	Assembly	Sticker remove & GMTs turn	Sewing Helper	0.26	1
21	Assembly	Drawsting insert through the waist channel	Sewing Helper	0.30	1
22	Assembly	Drawsting secure at CB waistband	BT	0.18	1
23	Assembly	Thread trims	Sewing Helper	0.35	1
–	–	–	Total	9.30	32

Operation Breakdown, SMV and Layout of Brooke Short Pant

SMV Summary of Brooke Short Pant

Sewing Helper	1.37
Sewing Machine	7.93
Sewing QI	0.00
Finishing I/M	0.00
Finishing QI	0.00
Poly Helper	0.00
Packing	0.00
Total	9.30

Machine Summary of Brooke Short Pant

4T OL Auto	8
OL Cutter	1
Flat Bed	3
SNL Auto	6
BT	2
SNDL Edge Cutter	1
DNL Lock Switch Auto	1
BH Auto	1
KNS	2
SNL[Chain STS]	2
Total	27

Man Power SUmmary of Brooke Short Pant

Sewing Helper	5
Sewing Machine	27
Sewing QI	0
Finishing I/M	0.00
Finishing QI	0
Poly Helper	0
Packing	0
Hand Tag	0
Total	32

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

No comments

Operation Breakdown, SMV and Layout of Brooke Skirt

By Nahian Mahmud Shaikat July 30, 2019 July 30, 2019 Apparel, Industrial Engineering (IE)

Operation Breakdown, SMV and Layout of Brooke Skirt

Efficiency = 42%
Total SMV = 7.9
Total Manpower Requried = 28
Total Number of Machine Required = 23

Seq. No	Body Part	Operation	Resource	SMV	Target (100%)	Layout MP
1	Front Part	Bottom binding n trims	Flat Bed	0.33	182	1
2	Assembly	Front n back part match	Assistant Operator	0.26	231	1
3	Assembly	Side seam	4T OL Auto	0.45	133	2
4	Assembly	Binding at one side to another around n trim	Flat Bed	0.90	67	3
5	Assembly	Mark and side seam topstitch	SNL Auto	1.00	60	3
6	Waist Belt	Elastic press,measure & cut	Sewing Iron	0.20	300	1
7	Waist Belt	Waistband join as a circle n mark	SNDL Edge Cutter	0.30	200	1
8	Waist Belt	Elastic join as a circle & mark	DNL Lock Switch Auto	0.30	200	1
9	Waist Belt	Mark n form hole at waistband	Snap	0.28	214	1
10	Assembly	Eyelet attach	Snap BA	0.35	171	1
11	Waist Belt	Sandwich elastic with waistband & tack	SNL Auto	0.40	150	1
12	Waist Belt	Waistband topstitch form channel	KNS	0.50	120	2
13	Waist Belt	Waist Band lower edges close & Mark	SNL [Chain STS]	0.45	133	2
14	Waist Belt	Attach waistband to the body	4T OL Auto	0.50	120	2
15	Label	Care label make	SNL Auto	0.24	250	1
16	Label	Label attach at WB	SNL Auto	0.35	171	1
17	Assembly	Sticker remove & GMTs turn	Assistant Operator	0.26	231	1
18	Assembly	Drawsting insert through the waist channel	Assistant Operator	0.30	200	1
19	Assembly	Drawsting secure at CB waistband	BT	0.18	333	1
20	Assembly	Thread trims	Assistant Operator	0.35	171	1
–	–	–	Total	7.90	–	28

Operation Breakdown, SMV and Layout of Brooke Skirt

SMV Summary of Brooke Skirt

Sewing Helper	1.37
Sewing Machine	6.53
Sewing QI	0.00
Finishing I/M	0.00
Finishing QI	0.00
Poly Helper	0.00
Packing	0.00
Hand Tag	0.00
Total	7.90

Man Power Summary of Brooke Skirt

Sewing Helper	5
Sewing Machine	23
Sewing QI	0
Finishing I/M	0.00
Finishing QI	0
Poly Helper	0
Packing	0
Hand Tag	0
Total	28

Machine Summary of Brooke Skirt

Flat Bed	4
4T OL Auto	4
SNL Auto	6
SNDL Edg Cutter	1
DNL Lock Switch Auto	1
Snap	1
Snap BA	1
KNS	2
SNL[Chain STS]	2
BT	1
Total	23

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

No comments

Operation Breakdown, SMV and Layout of Brooke Hoodies

By Nahian Mahmud Shaikat July 30, 2019 July 30, 2019 Apparel, Industrial Engineering (IE)

Operation Breakdown, SMV and Layout of Brooke Hoodies

Total SMV = 15.66
Total Manpower Requried = 56
Total Number of Machine Required = 45

Seq. No	Body Part	Operation	Resource	SMV	Layout MP
1	Assembly	Front n back part match	Assistant Operator	0.26	1
2	Assembly	Shoulder Join with/ without tape	4T OL Auto	0.36	1
3	Hood	Hood two part join	4T OL Auto	0.32	1
4	Hood	Hood band attach at hood opening	Flat Bed	0.35	1
5	Hood	Hood edge neaten	OL Cutter	0.26	1
6	Hood	Hood edges tack as circle	SNL Auto	0.24	1
7	Hood	Hood n body mark	Assistant Operator	0.30	1
8	Hood	Hood tack at neck	SNL Auto	0.26	1
9	Hood	Hood attach to body	4T OL Auto	0.35	1
10	Neck	Back neck binding	Flat Bed	0.30	1
11	Neck	Binding edges tack n cut	SNL Auto	0.36	1
12	Label	Label position mark	Assistant Operator	0.16	1
13	Neck	Back neck top stitch insert label	SNL Auto	0.40	1
14	Sleeve	Sleeve n body match	Assistant Operator	0.35	1
15	Sleeve	Insert Sleeves	4T OL Auto	0.56	2
16	Label	Care Label Make	SNL Auto	0.24	1
17	Assembly	Side/ sleeve seam insert care label	4T OL Auto	0.70	2
18	Cuff	Cuff join as a circleX2	SNL Auto	0.28	1
19	Cuff	Cuffs fold in half and mark	Assistant Operator	0.24	1
20	Cuff	Cuff attach at sleeve opening	4T OL Auto	0.50	2
21	Assembly	Bottom binding n trims	Flat Bed	0.50	2
22	Assembly	Front n back part match	Assistant Operator	0.26	1
23	Assembly	Side seam	4T OL Auto	0.45	2
24	Assembly	Binding at one side to another around n trim	Flat Bed	0.90	3
25	Assembly	Mark and side seam topstitch	SNL Auto	1.00	4
26	Waist Belt	Elastic press,measure & cut	Sewing Iron	0.20	1
27	Waist Belt	Waist band join as a circle n mark	SNDL Edg Cutter	0.30	1
28	Waist Belt	Elastic join as a circle & mark	DNL Lock Switch Auto	0.30	1
29	Waist Belt	Mark n make hole for eyelet	Snap	0.28	1
30	Waist Belt	Eyelet attach	Snap BA	0.35	1
31	Waist Belt	Sandwich elastic with waist band & tack	SNL Auto	0.40	1
32	Waist Belt	Waist band fold run stitch	SNL[Chain STS]	0.32	1
33	Waist Belt	Waist band lower edge close n mark	SNL[Chain STS]	0.45	2
34	Waist Belt	Attach waist band to body	4T OL Auto	0.50	2
35	Assembly	Top n bottom part match	Assistant Operator	0.28	1
36	Assembly	Top n bottom part tack	SNL Auto	0.30	1
37	Assembly	Top n Bottom attach together	4T OL Auto	0.50	2
38	Assembly	Sticker remove and GMTs turn	Assistant Operator	0.25	1
39	Cuff	Cuff top-stitch	2NDL FL	0.50	2
40	Assembly	Drawsting insert through the waist channel	Assistant Operator	0.30	1
41	Assembly	Drawsting secure at CB waist band	BT	0.18	1
42	Assembly	Thread trims	Assistant Operator	0.35	1
–	–	–	Total	15.66	56

Operation Breakdown, SMV and Layout of Brooke Hoodies

SMV Summary of Brooke Hoodies

Sewing Helper	2.95
Sewing Machine	12.71
Sewing QI	0.00
Finishing I/M	0.00
Finishing QI	0.00
Poly Helper	0.00
Packing	0.00
Hand Tag	0.00
Total	15.66

Man Power Summary of Brooke Hoodies

Sewing Helper	11
Sewing Machine	45
Sewing QI	0
Finishing I/M	0.00
Finishing QI	0
Poly Helper	0
Packing	0
Hand Tag	0
Total	56

Machine Summary of Brooke Hoodies

4T OL Auto	15
Flat Bed	7
OL Cutter	1
SNL Auto	12
SNDL Edg Cutter	1
DNL Lock Switch Auto	1
Snap	1
Snap BA	1
SNL[Chain STS]	3
2NDL FL	2
BT	1
Total	45

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

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