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

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

Operation Breakdown, SMV and Layout of Cody Manufacturing

Operation Breakdown SMV Layout of Cody Manufacturing

Cody basically wears under the blazer which ensures proper fit of blazer and gives a stylish look of a person. In this article we will share Operation breakdown, SMV and layout of Cody manufacturing where SMV is 28.14, the total manpower requirement is 88, and the number of machines required is 67.

Seq. NoBody PartOperationResourceSMVTarget (100%)Layout MP
1Front PartUpper body front two pannel match n join4T OL Auto0.401501
2PocketingPocket position markSewing Helper0.282141
3PocketingPress welt with fusing paper n markSewing Iron0.321881
4PocketingWelt attach at pocket position markSNL Auto0.521151
5PocketingPocket bag attachSNL Auto0.521151
6PocketingCut pocket mouth n form fishtailSewing Helper0.64942
7PocketingPocket liner attach at pocket positionSNL Auto0.521151
8PocketingWelt edge secure4T OL Auto0.203001
9PocketingSecure fishtaillsSNL Auto0.481251
10PocketingPocket bag close4T OL Auto0.521151
11PocketingPocket topstitch with corner closeSNL Auto0.68882
12PocketingTopstitch pocket bagsSNL Auto0.541111
13PocketingSecure pocket edgesSNL Auto0.321881
14Back PartUpper body centre back pannel match n join4T OL Auto0.252401
15Back PartTopstitch on CB seamSNL Auto0.351711
16Back PartUpper body back side two pannel match n join4T OL Auto0.401501
17AssemblyFront n back part matchSewing Helper0.252401
18AssemblyShoulder Join with/ without tape4T OL Auto0.282141
19AssemblyShoulder top-stitchSNL Auto0.302001
20AssemblySide seam4T OL Auto0.401501
21Back PartBack part mark for belt positionSewing Helper0.163751
22Back PartFusing attach at beltSewing Iron0.163751
23Back PartLeft n right side belt mark with templateSewing Helper0.203001
24Back PartLeft n right side belt make leaving open endSNL Auto0.68882
25Back PartLeft n right side belt turn with necessary scissoringSewing Helper0.302001
26Back PartLeft n right side belt topstitchSNL Auto0.68882
27Back PartBelt edge o/l4T OL Auto0.106001
28Back PartBelt edge secureSNL Auto0.163751
29Back PartBelt mark for attach with cross tackSewing Helper0.144291
30Back PartBelt attach with cross tackSNL Auto0.75802
31Back PartSecure belt joinBT0.242501
32Front PartLiner front two pannel match n joinSNL Auto0.401501
33Back PartLiner centre back pannel match n join4T OL Auto0.252401
34Back PartLiner back side two pannel match n join4T OL Auto0.401501
35AssemblyFront n Back panel matchSewing Helper0.252401
36AssemblyShoulder Join with/ without tape4T OL Auto0.262311
37AssemblyLiner side seam4T OL Auto0.361671
38LabelCare Label MakeSNL Auto0.222731
39LabelCare label tack at sideSNL Auto0.222731
40FacingFusing attach at facingFolding0.501202
41FacingArmhole facing circular joinSNL Auto0.481251
42AssemblyFacing n body markSewing Helper0.242501
43AssemblyArmhole facing tack to linerSNL Auto0.401501
44AssemblyArmhole facing attach to liner4T OL Auto0.451332
45AssemblyFacing join topstitchSNL Auto0.601002
46AssemblyBottom facing edges joinSNL Auto0.242501
47AssemblyFacing attach at bottom4T OL Auto0.302001
48AssemblyFacing join topstitchSNL Auto0.451331
49AssemblyBack neck n front facing edges joinSNL Auto0.282141
50AssemblyFacing n body markSewing Helper0.282141
51AssemblyFacing tack to bodySNL Auto0.401501
52AssemblyFacing attach to front n back neck4T OL Auto0.561072
53AssemblyFacing join topstitchSNL Auto0.70862
54LabelLabel position markSewing Helper0.144291
55LabelLabel MakeSNL Auto0.203001
56Back PartLabel attach at back neckSNL Auto0.321881
57AssemblyUpper n liner part tack at
underarms, bottom, shoulder neck point n front
SNL Auto0.80752
58AssemblyUpper n liner part seam tack at the bottomSNL Auto0.501201
59AssemblyUpper n liner part attach leaving an open edge4T OL Auto1.10553
60AssemblyBluffstitch on upper n liner part attach seamSNL Auto1.30463
61AssemblyHand to turn upper n liner partSewing Helper0.401501
62AssemblyClose open endSNL Auto0.321881
63AssemblySticker remove and GMTs turnSewing Helper0.154001
64AssemblyTopstitch around n armholeSNL Auto1.40433
65Front PartMark n make the buttonholeBH Auto0.501202
66Front PartMark for buttons x 5Sewing Helper0.154001
67Front PartButton attach x5 + 1 spareBA Auto0.481252
68AssemblyThread trim n button closeSewing Helper0.401502
Total28.1488
Operation Breakdown, SMV and Layout of Cody Manufacturing

SMV Summary of Cody Manufacturing

Sewing Helper4.96
Sewing Machine23.18
Sewing QI0
Finishing I/M0
Finishing QI0
Poly Helper0
Packing0
Hand Tag0
Total28.14

Man Power Summary of Cody Manufacturing

Sewing Helper21
Sewing Machine67
Sewing QI0
Finishing I/M0.00
Finishing QI0
Poly Helper0
Packing0
Hand Tag0
Total88

Machine Summary of Cody Manufacturing

4T OL Auto20
SNL Auto42
BT1
BH Auto2
BA Auto2
Total67

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