nms

## 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

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
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

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.

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.

### 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.

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

## 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.

### 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

### 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

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

## 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]

## 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]

## 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

### 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]

## 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

### SMV Summary of Kids Overall Hoodie

 Sewing Helper 4.86 Sewing Machine 16.74 Sewing QI 0 Finishing I/M 0 Finishing QI 0 Poly Helper 0 Packing 0 Hand Tag 0 Total 21.6

### Manpower Summary of Kids Overall Hoodie

 Sewing Helper 18 Sewing Machine 59 Sewing QI 0 Finishing I/M 0 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]

## 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

### SMV Summary of Brooke Short Pant

 Sewing Helper 1.37 Sewing Machine 7.93 Sewing QI 0 Finishing I/M 0 Finishing QI 0 Poly Helper 0 Packing 0 Total 9.3

### 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 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]

## 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

### SMV Summary of Brooke Skirt

 Sewing Helper 1.37 Sewing Machine 6.53 Sewing QI 0 Finishing I/M 0 Finishing QI 0 Poly Helper 0 Packing 0 Hand Tag 0 Total 7.9

### Man Power Summary of Brooke Skirt

 Sewing Helper 5 Sewing Machine 23 Sewing QI 0 Finishing I/M 0 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]

## 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

### SMV Summary of Brooke Hoodies

 Sewing Helper 2.95 Sewing Machine 12.71 Sewing QI 0 Finishing I/M 0 Finishing QI 0 Poly Helper 0 Packing 0 Hand Tag 0 Total 15.66

### Man Power Summary of Brooke Hoodies

 Sewing Helper 11 Sewing Machine 45 Sewing QI 0 Finishing I/M 0 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]