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

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

 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

 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]

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. No Body Part Operation Resource SMV Target (100%) Layout MP 1 Front Part Upper body front two pannel match n join 4T OL Auto 0.40 150 1 2 Pocketing Pocket position mark Sewing Helper 0.28 214 1 3 Pocketing Press welt with fusing paper n mark Sewing Iron 0.32 188 1 4 Pocketing Welt attach at pocket position mark SNL Auto 0.52 115 1 5 Pocketing Pocket bag attach SNL Auto 0.52 115 1 6 Pocketing Cut pocket mouth n form fishtail Sewing Helper 0.64 94 2 7 Pocketing Pocket liner attach at pocket position SNL Auto 0.52 115 1 8 Pocketing Welt edge secure 4T OL Auto 0.20 300 1 9 Pocketing Secure fishtaills SNL Auto 0.48 125 1 10 Pocketing Pocket bag close 4T OL Auto 0.52 115 1 11 Pocketing Pocket topstitch with corner close SNL Auto 0.68 88 2 12 Pocketing Topstitch pocket bags SNL Auto 0.54 111 1 13 Pocketing Secure pocket edges SNL Auto 0.32 188 1 14 Back Part Upper body centre back pannel match n join 4T OL Auto 0.25 240 1 15 Back Part Topstitch on CB seam SNL Auto 0.35 171 1 16 Back Part Upper body back side two pannel match n join 4T OL Auto 0.40 150 1 17 Assembly Front n back part match Sewing Helper 0.25 240 1 18 Assembly Shoulder Join with/ without tape 4T OL Auto 0.28 214 1 19 Assembly Shoulder top-stitch SNL Auto 0.30 200 1 20 Assembly Side seam 4T OL Auto 0.40 150 1 21 Back Part Back part mark for belt position Sewing Helper 0.16 375 1 22 Back Part Fusing attach at belt Sewing Iron 0.16 375 1 23 Back Part Left n right side belt mark with template Sewing Helper 0.20 300 1 24 Back Part Left n right side belt make leaving open end SNL Auto 0.68 88 2 25 Back Part Left n right side belt turn with necessary scissoring Sewing Helper 0.30 200 1 26 Back Part Left n right side belt topstitch SNL Auto 0.68 88 2 27 Back Part Belt edge o/l 4T OL Auto 0.10 600 1 28 Back Part Belt edge secure SNL Auto 0.16 375 1 29 Back Part Belt mark for attach with cross tack Sewing Helper 0.14 429 1 30 Back Part Belt attach with cross tack SNL Auto 0.75 80 2 31 Back Part Secure belt join BT 0.24 250 1 32 Front Part Liner front two pannel match n join SNL Auto 0.40 150 1 33 Back Part Liner centre back pannel match n join 4T OL Auto 0.25 240 1 34 Back Part Liner back side two pannel match n join 4T OL Auto 0.40 150 1 35 Assembly Front n Back panel match Sewing Helper 0.25 240 1 36 Assembly Shoulder Join with/ without tape 4T OL Auto 0.26 231 1 37 Assembly Liner side seam 4T OL Auto 0.36 167 1 38 Label Care Label Make SNL Auto 0.22 273 1 39 Label Care label tack at side SNL Auto 0.22 273 1 40 Facing Fusing attach at facing Folding 0.50 120 2 41 Facing Armhole facing circular join SNL Auto 0.48 125 1 42 Assembly Facing n body mark Sewing Helper 0.24 250 1 43 Assembly Armhole facing tack to liner SNL Auto 0.40 150 1 44 Assembly Armhole facing attach to liner 4T OL Auto 0.45 133 2 45 Assembly Facing join topstitch SNL Auto 0.60 100 2 46 Assembly Bottom facing edges join SNL Auto 0.24 250 1 47 Assembly Facing attach at bottom 4T OL Auto 0.30 200 1 48 Assembly Facing join topstitch SNL Auto 0.45 133 1 49 Assembly Back neck n front facing edges join SNL Auto 0.28 214 1 50 Assembly Facing n body mark Sewing Helper 0.28 214 1 51 Assembly Facing tack to body SNL Auto 0.40 150 1 52 Assembly Facing attach to front n back neck 4T OL Auto 0.56 107 2 53 Assembly Facing join topstitch SNL Auto 0.70 86 2 54 Label Label position mark Sewing Helper 0.14 429 1 55 Label Label Make SNL Auto 0.20 300 1 56 Back Part Label attach at back neck SNL Auto 0.32 188 1 57 Assembly Upper n liner part tack at underarms, bottom, shoulder neck point n front SNL Auto 0.80 75 2 58 Assembly Upper n liner part seam tack at the bottom SNL Auto 0.50 120 1 59 Assembly Upper n liner part attach leaving an open edge 4T OL Auto 1.10 55 3 60 Assembly Bluffstitch on upper n liner part attach seam SNL Auto 1.30 46 3 61 Assembly Hand to turn upper n liner part Sewing Helper 0.40 150 1 62 Assembly Close open end SNL Auto 0.32 188 1 63 Assembly Sticker remove and GMTs turn Sewing Helper 0.15 400 1 64 Assembly Topstitch around n armhole SNL Auto 1.40 43 3 65 Front Part Mark n make the buttonhole BH Auto 0.50 120 2 66 Front Part Mark for buttons x 5 Sewing Helper 0.15 400 1 67 Front Part Button attach x5 + 1 spare BA Auto 0.48 125 2 68 Assembly Thread trim n button close Sewing Helper 0.40 150 2 – – Total – 28.14 – 88

SMV Summary of Cody Manufacturing

 Sewing Helper 4.96 Sewing Machine 23.18 Sewing QI 0 Finishing I/M 0 Finishing QI 0 Poly Helper 0 Packing 0 Hand Tag 0 Total 28.14

Man Power Summary of Cody Manufacturing

 Sewing Helper 21 Sewing Machine 67 Sewing QI 0 Finishing I/M 0 Finishing QI 0 Poly Helper 0 Packing 0 Hand Tag 0 Total 88

Machine Summary of Cody Manufacturing

 4T OL Auto 20 SNL Auto 42 BT 1 BH Auto 2 BA Auto 2 Total 67

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