Operation Breakdown, SMV and Layout of Chino Pant Manufacturing
Chino Pants is one of the commonly worn cloth preferable by both male and female as a casual dress which is made from 100% cotton. Trouser is a well-known product which is a chino pant. Here in this article, you will have a detailed idea of operation breakdown, SMV and layout of chino pant manufacturing. For chino pant total SMV is 36.86 and number of operator and helper requirement is 92.
A blazer is a type of jacked which is preferable by both male and female as a formal dress. Here in this article, you will have an idea of operation breakdown, SMV and layout of blazer manufacturing. As a garments (blazer) manufacturer you must know this. The total SMV is 21.85, Manpower requirement is 79 and the number of machines is 55.
Operation Breakdown, SMV and Layout of Blazer Manufacturing
The shirt is one of the commonly worn dress all over the world. For a target level of garments manufacturing, you need to identify the operation breakdown, manpower requirement, and machine requirement. So that you can do proper production planning. Here in this article, we will share Operation breakdown, SMV and layout of Shirt Manufacturing where Total SMV is 33.84, manpower requirement is 100 and the total machine required 81 unit.
Operation breakdown, SMV and layout of Shirt Manufacturing
Working Hour: 1
Pitch Time: .31
attach at front placket
Front placket mark n press
Placket make upper
Placket make Lower
Upper placket 1/4 top- stitch
Deco. Placket press
Front n back part match
Shoulder join with/ without tape
4T OL Auto
Fusing attach at collar/collar stand
Corner cut n turn collar
Collar 1/4 topstitch
Collar edge close n cut
Collar band rolling
Mark n arrange match collar with band
attach with collar band sandwich stitch
Collar band turn n press with necessary scissoring
QMS Department Job Responsibilities of Garments Industry
Garments QMS Department
QMS is a quality management system based on customer requirements, system, and management of quality control and assurance. Garments manufacturers have to comply with buyer QMS / Technical Requirements, no way to avoid it if they want to continue business buyer. QMS or technical audit score effect on business, lower scores factory lose orders or marked in reject list one time. All buyers set QMS guideline for their vendor/ Supplier. QMS department is responsible for buyer QMS requirements implementation. QMS Audit is also known as Technical Audit in the apparel industry. QMS Audit going to be important like social compliance audit of Garments manufacturing factory. Quality management system plays a vital role to Develop quality of the industry. QMS department is a part of quality engineering. QMS department is Responsible for all quality, technical audit and process audit of the apparel industry.
Job Description of Garments QMS Department
Follow up, monitor and supervise QMS requirements
To run successfully QMS throughout the whole manufacturing unit from warehouse to shipment.
Lead quality control and management system in cutting, sewing, and finishing
Train up all quality inspector, quality staff about basic quality requirements, quality concept, and quality policy.
Develop quality SOP, quality Manual for good quality management.
Total Quality Management, Implementation and Continual Improvement.
Implement all technical requirement of the buyer for technical audit.
Doing internal QMS/ Technical Audit being internal auditor, work with all section head for improvement.
Keep all quality documentation & SOP of quality.
Manage & monitor trims & accessories inspection department & work with the merchandising team to reduce defects from the supplier end.
Implement 5S housekeeping in workplace and train every department about 5S.
Manage & monitor sample department for on-time sample submission, quality & changes in the sample for better productivity & quality.
Manage & monitor quality department of Cutting, Sewing & Finishing sections.
Implementation of appropriate Quality procedure in every section & manpower based on it.
Manage & monitor training for all quality personnel for better quality.
Work with Buying QC for a better understanding of quality requirement & present during the audit.
All types of Quality Metrics & KPI reporting
Conduct technical, quality seminar and coaching.
Technical Files and Document Control
Implement Lean manufacturing and Six Sigma to improve quality.
Implement traffic light system in the sewing line to track and control operator wise defect.
Needed for QMS Job
Critical problem solving
Good analytical knowledge
Good communication skill
Technical skill on the quality issue
Statistical and data-driven quality control
Good command on excel and PowerPoint
Designations of Garments
Those jobs are available in Bangladesh to do work QMS
department of Garments; woven, knit and sweater factory.
CM loss at Marketing $3,933.0123 [Dec’18-Feb’19]. Only Buyer ‘Promodoro’ Marketing CM gain $5.8259.
Average Marketing SMV & Average Sewing SMV difference 0.21. SMV used in production less than Marketing, which is a positive fact to gain profit.
CM loss of Unit-01 & Unit-03 in production, use of more manpower than Marketing, the achievement of less efficiency than Marketing are the reasons for the loss in CM.
In Unit-02, efficiency gain (52.08%) is more than expected (43.08%) but used CM is more than Marketing & Less than Plan target CM. If there was no loss during Marketing, CM gain would be profitable.
Efficiency variation avg 2.40% than expected which results in total CM loss.
CM based target need to establish for-profit gain in CM.
The capacity calculation/ projection should be followed by CM considering SMV, Manpower, Working hour, Efficiency as well as Quality.
CPM should be standardized/similar for all buyer & all units.
The Necessity of CM Based Target Set-up
Currently, Garments profit calculation based on FOB. But in practice, it is the total performance of Textile, Fabric finishing, sewing, printing, embroidery, Garments finishing, logistics, etc. & investors profit percentage, deficiency cost.
Profit calculation & evaluation will be equal for all units.
CM based target can be used for other units like Textile, AOP, Finishing, Dyeing, etc. to measure performance more precisely.
Pre-activities for CM Based Capacity Allocation which we Want to do for Future
Washing is a process which is done in denim garments for increasing its value. It also makes the garment comfortable for the users. Denim without a wash is not always user-friendly. Washing increases the outlook of denim garments added extra value to the customer. A better-washed product ensures a higer standard of denim. Purpose to purpose washing varies and outlook of denim also varies because of different washing methods.
Flow Chart of Denim Washing
Types of Denim Washing Process
There is two widely used process of washing denim. One is a dry process and other is a wet process.
3. Acid Wash
6. Rinse Wash
This process is done in the unwashed condition. Basically, denim garments are treated here but nowadays twill garments are also treated.
Whisker is the most common dry process for denim garments. This is done by making a pattern and put the garments then remove the color from the pattern area. After wash, we can see the pattern mark. It is one kind of design on the garments.
This whisker is done in a manual way with the help of a pattern. On denim garments, we have done it by abrasive paper.
Material Needed for Manual whisker
Abrasive paper For work, a worker is used different types of abrasive paper. Like as – I) P-320 (for very rough surface) II) P-400 (for very rough surface) III) P-600(for less rough surface) IV) P-800 (for medium surface)
The Procedure of Manual whisker
Put the whisker pattern into the garments
Then rub the pattern area according to standard intensity by abrasive paper
This whisker is done by laser machine. Here, garments specific area are burned by imposing laser with high intensity. After wash, the burned indigo color will be removed and whisker effect will be visible.
The Procedure of Laser Whisker
Making the design by Photoshop/illustrator
Put the garments on the machine surface
Set the intensity of the burn
Burn the garments
Required Equipment’s for Laser Whisker
Leather hand gloves and goggles for safety.
This process is used to remove/fade the color from a specific area of the garments with an abrasive paper. The faded effect is nicely visible after wash.
Required Tools for Hand Scrapping
Chalk for marking and masks
Working Procedure of Hand Scrapping
Specify the area
Put the garments into dummy
Scrapping with emery paper
Potassium Permanganate is sprayed on the garments at a specific area. Garments are placed on a dummy first and then pp spraying is done with the help of gun by air pressure. After that garments are dried and finally neutralize it to get the desired effect.
Materials Needed for P.P Spray
The procedure of P.P Spray
Placement on dummy
Tagging or tacking is the process which is done at the unwashed condition of garments. After wash, we will get its effect. The maximum time we will do it at edge area by folding the garments. Sometimes this process damages the garments by creating a hole.
Materials Needed for Tagging
Procedure of Tagging
Marking the garments
Fold the garments as per standard
Then tag the garments
This process is done by pen grinding machine which destroys only the warp yarns of the fabrics or garments. The destroy look on the garments is best viewed after washing.
Necessary Tools to Destroy
Pen grinding machine
Working Procedure of Destroy
Marking the area
Destruct the garments by pen grinder
Check the quality
This process is done at edges area of garments. If the garments require two-time wash in that case grinding is done after the first wash to avoid the damages of garments.
Materials Needed for Grinding
Hand gloves for safety.
Procedure of Grinding
Run the machine
Touching the edge of garments according to standard.
This process is done by crinkle machine or by manual clipping of a specific area and the effect is more visible at front and back knee area.
This process is done by crinkle machine or by manual clipping of a specific area and the effect is more visible at front and back knee area. In this process, the two-dimensional effect is produced.
Material Needed for Crinkle
Process flow of 2D Crinkle
Garment Placement on machine
Squeeze the garments
Keep it up to retention time (Curing)
This effect is found by the special treatments of garments. By this system, the 3-dimensional effect is produced. The final is more visible after washing the garments.
Tools used in 3D Crinkle
3D crinkle machine
The procedure of 3D Crinkle
Placement into dummy
Make 3D crinkle as per standard
Pre-cure the garments at 90 degrees C
Taken out the garments from the machine
Put into curing oven for full cure
This types of processes are done at the wet condition. There are so many stages in the wet process.
This wash is the combination of rinse wash and softener wash.
The purposes of Normal Wash
To remove dust, oil spot, and other impurities.
To make the garments soft.
Problems of Normal Wash
Sometimes pocket staining may occur.
Colorfastness may be failing.
Tone change if wash time is increased.
In this wash, the enzyme is used to create the desired effect. They work basically on the surface of the fabric. The enzyme may be neutral or acidic according to the requirement of shade. The main benefits of using enzyme are that it is biodegradable and hence eco-friendly.
Purpose of Enzyme wash
To remove size and starch materials.
To make the garments softer.
To improve fastness and anti-pilling properties.
Stone Enzyme Wash
Stone and Enzyme are used together for washing. Heavy abrasion occurs in this wash. Typically done for Denim garments.
Problems of Stone Enzyme Wash
Sometimes metal may be found after using stone.
Hem and seam area can be damaged.
In bleach wash, a strong oxidative bleaching agent is added during the washing, with or without pumice stones.
Acid washing or ice washing is usually done by dry tumbling the garments with pumice stones presoaked in an acid solution.
Problems of Acid Wash
Wide variation in effect.
PP spot may come.
Garments can be damaged due to vigorous action.
Specifications of Front Loading Machine
Specifications of Top Loading Machine
Specifications of Hydro Extractor Machine
Model : TG-25
Diameter of Drum (diameter x depth)
P; 220V/60HZ/3 P;
P; 415V/50HZ/3 P
Another Specifications of Hydro Extractor Machine
Model : RA-29
The diameter of Drum (diameter x depth)
P; 220V/60HZ/3 P;
P; 415V/50HZ/3 P
Lean Manufacturing Initiatives
in Apparel Industry
This article is about very basic of lean manufacturing, definition, principle, importance, and steps how you take initiatives to introduce to lean manufacturing in your garments manufacturing industry. Hope this writing would help you to get an idea of Lean Manufacturing initiatives.
What is Lean?
A lean is a way of maximization of the benefit by ensuring proper utilization of resources without increasing its cost or wasting any materials. This is a systematic approach to minimizing the cost of any process that can be applicable for production or service-oriented companies. Lean manufacturing is nowadays commonly used the term in the apparel industry. The main objective is to reduce the production cost of garments. Although all companies using a systematic approach of lean manufacturing to reduce the wastage and maximize productivity but they do not name as a lean. Finally, we can say lean is a tool that uses a systematic approach to minimize the production cost which ultimately increases the productivity and overall profit of the company.
Principles of Lean Manufacturing
Recognition of waste
Standard the process
Quality at source
Value-define by the customer
Why Lean is Important for the Company?
It helps to eliminate the waste
Makes a better environment at home & office.
Change the culture
To take the challenge of future business
Steps of Lean Manufacturing
Value stream mapping
Kaizen- continuous development
Quick change over- small quantity
Overall equipment effectiveness- maximum utilization of people instead of mc
Six Sigma- statistical method of systemic analyze to reduce process variation use damic.
Total productive maintenance- all level of function to maximize OEE
Keys to Lean Success
Prepare & motivate people
Identify & empower champions
Atmosphere of experiments
Lean Manufacturing Initiatives
for Garments Manufacturing
Lean awareness meeting
data gathering analysis
Gathering data’s from the store, cutting
Gathering data’s from sewing & finishing
Gathering data’s from washing
Train the core team about the lean concept
Material & information flow from store ship
Send all the report to assessment by lean responsible
Draw the Value Stream Mapping of SIL the Current state
Draw the Value Stream Mapping of SWWL the Current state
Get the assessment report
Describe how to make the lean storyboard, waste poster & others
Describe how to make the presentation
Design the Lean storyboard and the project office
Design new posters related to the waste Illustration
Gather the first Core implementation Team and assign them the task to find out the waste in their departments.
Fill the Waste posters with them according to the type of waste under related departments
Reevaluate the assessment data Washing only(inventory)
Set a training calendar for middle management split into four sessions of training
Develop the first presentation for top and middle management
Arrange the first Training session-1 for the management(recognize the waste)
Evaluate the marks.
Analyze the process razing at the cutting
Analyze the process razing at the washing
Draw the Value Stream Mapping of the Current state
Develop the Future Value Stream Mapping
Develop the second presentation for top and middle management
Arrange the Training session-2 for the management(How to see the waste)
Evaluate the marks.
Develop the third presentation for top and middle management
Arrange the Training session-3 for the management(How to think)
Evaluate the marks.
Develop the fourth presentation for top and middle management
Arrange the Training session-4 for the management(How to develop)
Evaluate the marks.
Plan session with management to find the root cause of the each and every waste
Fill the “Tools” sheet in “Kaizen event Master file” with the root causes and send to Lean leader
Visit for the role of the steering committee for lean
Team selection, leader selection & their activities training/ meeting with steering committee/ making operator training calendar/ train the operator for lean/5s, etc.
start operator training for multiskilling/make format for training/ 5s in Bangla/ Arrange training program for staffs for Needs for change/discuss with all PM for process standardization& sledding. Inform lean officer for next presentation/ training session with all line chief & floor managers
Training program for Composition of SMV/ cross training for operator/attachments for a machine.
Training program for Types of waste/ wasteful motions/ cross training for operator/attachments for machine/ searching machine
Training program for practical waste full motion on the line/ Charles assessment review & findings.
Conduct a meeting for Economical & simultaneous motion/ Quality system of the line.
Training program for Engineering sheet / Line chief& supervisor/ Martine visit the factory / Cross training for the operator
Training program for machine adjustment/ Training program for calculation KPI’s / Line chief& supervisor/ Martine visit the factory / Cross training for the operator/ 4th training session for steering committee “How to Develop?”
Report making / Marking & evaluation/ and visit the plant
Team selection from finishing, leader selection & their activities training/ train the operator for lean/5s, etc.
Start training session for team #A for just in time/ Understand 5s
Training program for Composition of SMV & workplace development/different types of waste in the workplace & how to create continuous flow/ discuss with Mr. Aminul regarding QA procedure & arrange a meeting for continuous movement of the garments.
Training about wasteful motion(theory & practical)
Lean awareness training for finishing team A QC’s, Lean awareness training for team # 10 front & bk at(2 to 3 pm & assemble 3-4 pm).
Economical & simultaneous Motion for the team leader, supervisor in finishing team #A, a Quality system of the line & product training for the team leaders & supervisors. Train the operator QA, sup of team # 5 in two groups (front & bk 2to 3 & assemble 3-4 pm)
Training about operation breakdown, critical path, quality & tool (work aids), worker balance, Layout & machine requirements.
Training in finishing Btn area for 5s & lean concept & cross training in team #A
Job Responsibilities of Inline Quality
Inspector of Apparel Industry
Inline Quality Inspector
The inline quality inspector checks garments in-process sewing and finishing production line. End product quality depends on inline quality control which done as soon as an operation complete, it can be called online quality control. If inline quality inspector gets a defect, the product never goes the next process without rectification, that’s the importance of Inline quality control because ratification of end garments is almost impossible.
Responsibilities of Inline Quality Inspector of Garments
Check the complete operations necessary for passing a new style.
Must keep a measuring tape, specs sheets, Alter stickers and inline reports during the inline checking.
Make sure either all terms are available or not.
Make sure cleanliness of the machines
If any needle is making holes then must change it and use the needle according to the requirement of the garment.
Point out the damaged (out of order) machines and try to make in order
Otherwise, take the machine out of flow or mark it as (out of order).
Check the sewing thread shades according to PPC file and matching.
Must check the garments that either these are according to quality standards after the maintenance of machines.
Confirm the trims attachments are passed e.g. Collar cuff, tapes, buttons, labels Placket, and sleeves, etc.
Operation Breakdown, SMV and Layout of Jogger Manufacturing Process
A jogger is a casual bottom item; Welt pocket is an inside pocket with bone covered in the mouth. Here given all operation list sequence wise of jogger manufacturing. Here jogger total SMV is 19.61, 72 manpower required. This Operation Breakdown is done by LOGIC ERP software, used to prepare operation bulletin & m/c layout & others departmental jobs as well. There is a data bank, style SMV analysis, machine layout & operation balancing. This LOGIC ERP database can be linked with other software & web for different uses.