Operation Breakdown SMV and Layout of Chino Short Pant

SMV indicates the Standard Minute Value, that is standard time required to make a particular garments. On the basis of SMV you can calculate your cost of your garments and planning to set target of production. Chino short pant SMV is 37.42 and 69 sewing machine will be needed. We shared operation bulletin of Chino long pant in past, now we are sharing Operation Breakdown SMV and Layout of Chino Short Pant.

Operation Breakdown, SMV and Layout of Chino Short Pant Manufacturing

Operation Breakdown SMV and Layout of Chino Short Pant Manufacturing

SL.OPERATIONSMVTGT
FRONT
1O/L at fr.rise 0.30200
2Bone joint with fr part0.6790
3Corner cut 0.40150
4Tack at pkt mouth posn0.6790
5Top stt. At pkt mouth posn0.7580
6Coin pkt close 0.38160
7Safety tack at  pkt beg corner & W/b Side0.40150
8 Pocketing  matching0.50120
9Facing joint with Fr  pkting0.40150
10Pocketing attach at pocket mouth0.50120
11Front pocket mouth top stitch0.50120
12Tack at pkt mouth posn0.43140
13Fr pkt bag close by O/L0.60100
14pocket bag side tack0.60100
15Fr pkt bag 1/4 top stt0.60100
16Pockting & sheel body fab att.at w/b side0.7580
17O/L at fr.rise 0.30200
18D/ply make & turn over0.40150
19S/ply & d/ply piping (use folder)0.40150
20S.ply att. +  1/8  top stt. 0.60100
21Zipper joint at s.ply0.50120
22J stt  with mark0.6790
23D. ply att with zipper 0.50120
24Fr zip 1/16″ top stt 0.60100
25High top stt0.60100
26Care label attach 0.60100
27Total  5.17
SL.BACK PART SMVTGT
1Mark flap for making 0.60100
2Flap making (BK)0.40150
3Flap turn 0.6790
4Scissoring at flap0.6790
51/4 Top  stt at Bk pkt flap0.6790
6Mark at bk part fr dart & bone joint0.55110
7Dart making0.46130
8Top stt. At Dart posn0.40150
9Bk pockting o/l0.40150
10Bk pockting att. At bk part0.50120
11Bone making0.46130
12Mark at bone fr joint0.50120
13Bone & Flap joint0.6790
14Bone cutting1.5040
15Bone mouth inside tack0.7580
16Bone mouth top lower stt0.7580
17Facing joint at bk pockting(Bone side)0.55110
18Bone mouth top upper stt0.6790
19Facing joint at bk pockting0.55110
20Bk pkt close1.5040
21Tack at bk pocket upper side0.40150
22Back rise joint0.35170
23top stt at Back rise joint posn0.50120
24Total  14.45
SL.ASSEMBLY SMVTGT
1Fr to Bk part match0.48125
2Side seam0.50120
3Belt Contrast part fusing0.6790
4Belt piping (use folder)0.40150
5Chine stt. At w/b contrast part0.40150
6Two (LOGG & Size) lbl joint0.30200
7Main lbl joint at  w/b contrast part0.50120
8potty joint at w/b btn att posn1.0060
9Extra loop Iron0.30200
10Extra loop Att. At bk rise0.35170
11Belt match0.50120
12Waist belt iron ( use folder)0.50120
13Belt two part joint0.50120
14Body mark for loop att.0.40150
15Loop making0.40150
16Loop mark & cut0.60100
17Lbl joint at loop0.6790
18Loop attach lower side0.60100
19Belt joint ith body0.60100
20False tack at w/b 0.60100
21Top att at w/b lower side0.7580
22Name lbl & care lbl joint0.46130
23Mouth cut+  trim0.50120
24Mouth close in side0.7185
25Mark for zipper psn  + thread open at mouth0.7580
26Mouth close top side0.60100
27Inseam0.60100
28Inseam top stt.0.55110
29Elastic cutting & mark for joint0.6790
30Elastic Tack 0.6790
31Leg hem0.7580
32Loop attach upper side0.60100
Total 17.86
G TOTAL37.47
                  MANPOWER REQUIREMENT Number
Snap = 0
S/N    =52
O/L   =8
D/N   =3
F/O/A  =0
BARTACK   =0
K/S   =0
C/S    =6
  HELPER   =20
IM   = 2
TOTAL MANPOWER91
L/C   =1
S.VISOR  = 3
TOTAL MANPOWER95

Written by

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

Linkedin: A.M. Amirul Islam

Implementation of Lean Manufacturing in Garments Factory

A Successful Implementation of Lean Manufacturing in Garments Factory Works as a Driving Force to Ensure Effectiveness in Operation

What is Lean Manufacturing?

Lean manufacturing is a systematic methodology to eliminate waste (non-value-added activities) by the continuous improvement which adds value to the customer and surely in manufacturing as well but without hampering productivity. Lean Manufacturing is all about the optimizing processes, eliminating waste; eliminating inventory, building a quality product, more efficient workplace with less cost and human effort. The manufacturing system is work for customer satisfaction and optimization of all resources.

Implementation of Lean Manufacturing in Garments Factory

Benefits of Lean Manufacturing

The benefits and advantages of lean manufacturing will be more clear to you after reading this below mention list:

  1. Improve productivity and quality
  2. Reducing Work in Process (WIP) inventory.
  3. Eliminate waste and problems
  4. Reducing inventory area
  5. Reduce cycle and lead time
  6. Production flow and controlled automation
  7. Reduce manpower, time and space
  8. Improve visual management
  9. Reducing machine downtime
  10. Optimize resources
  11. Sustainability, employee satisfaction, and increase profit
  12. Improve workplace and organize.
  13. Improve safety conditions and housekeeping.
  14. Increase customer satisfaction and customer service

Principles of Lean Manufacturing

5 principles of lean manufacturing can be applied in any manufacturing industry.

  1. Define Value
  2. Map the Value Stream
  3. Create Flow
  4. Establish Pull
  5. Pursue Perfection

Lean Manufacturing Tools Used in Garments Industry

  1. 5S
  2. KPIs
  3. Bottleneck Analysis
  4. Kanban Board
  5. Visualize management system
  6. 7 Wastages in manufacturing
  7. Value stream of a product
  8. Gemba
  9. Continuous Improvement- Kaizen
  10. Total Quality Management (TQM)
  11. Pareto Analysis
  12. Root Cause Analysis
  13. Continuous Flow
  14. Right First Time
  15. A3 Problem Solving
  16. PDCA (Plan, Do, Check, Act)
  17. Muda (Waste)
  18. Overall Equipment Effectiveness (OEE)
  19. Standardized Work
  20. Poka-yoke (Mistake Proofing)
  21. Cellular manufacturing
  22. Total Productive Maintenance (TPM)
  23. Zero quality defects

5S

5S is the first step to implement lean manufacturing, it helps to keep workplace organize and clean. It is actually tools of continuous improvement.

We have two articles on 5S you may love to read

KPIs

Key Performance Indicator (KPI) is a performance measuring tool which helps to know about a company the situation of their achieving goals and data of their performance.

You may love to read this detail article: KPI Factors of Garments

Bottleneck analysis

Bottleneck is a process which is the slowest among manufacturing all process hampering production. Bottleneck analysis very much important for garments sewing and finishing section, because it has effects on production flow.

Kanban Board

Kanban is visual display board for visualizing to do list, command what to do to reduce overproduction in the manufacturing floor. 

Please read this article to know more about it. Kanban Board in Garments Manufacturing Production Floor

Visualize Management

Visual management need for an organization that provides information for everybody who can analyze large amounts of data and produce reports that provide meaningful value. Visualization could become the remedy for generating actionable information for the apparel industry.

Please read this article to know more about it. Visual Management System in the Apparel Industry

7 Wastages

Waste is the use of resources over and above what is actually required to produce the product as defined by the customer. Lean manufacturing reduce 7 wastages in types of manufacturing, 7 wastages (Mudas) are:

  1. Transport
  2. Inventory
  3. Motion
  4. Waiting
  5. Over-Processing
  6. Overproduction
  7. Defects

Value Stream of a Product

Value stream mapping is a lean manufacturing or lean enterprise technique used to document, analyze and improve the flow of information or materials required to produce a product or service for a customer.

Gemba

Gemba is Japanese terms which mean to go actual problem occurring place, ask and collecting information from a real place rather than just sitting in the office and depending on other people to collect data.

Continuous Improvement

Continuous Improvement is a philosophy of never-ending improvement. Continuous improvement is an ongoing effort to improve products, services or processes. These efforts can seek “incremental” improvement over time or “breakthrough” improvement all at once.Read more from Continuous improvement

Please read this article to know details about it Implementation of 7 QC tools in the apparel industry

Total Quality Management (TQM)

Total quality management is the management approach of an organization, centered on quality, based on the participation of its entire membership and aiming at long term success through customer satisfaction.  TQM is long time oriented teamwork that requires leadership of top management and continuous involvement.  

Philosophy of TQM

Customer focusA goal is to identify and meet customer needs
Continuous improvementA Philosophy of never-ending improvement
Employee empowermentEmployees are expected to seek out, identify and correct quality problems
Use of quality toolsOngoing employee training in the use of quality tools
Product designA product needs to be designed to meet customer expectations.
Process managementQuality should be built into the process; the source of quality problems should be identified and corrected.
Managing supplier qualityQuality concepts must extend to a company’s suppliers

Pareto Analysis

Pareto Analysis named after the Italian economist, Vilfredo Pareto. The original observation was in connection with population and wealth. Pareto analysis is also known as 80/20 rule. Vilfredo Pareto observed that 80% of Italy’s land (Asset) was owned by 20% of the people. In the late 1940s, Dr. Joseph M. Juran, a Quality Management pioneer, applied this 80/20 Rule to quality control, calling it Pareto’s Principle. Pareto analysis is very much helpful for reducing garments defects that indicate 80% problem happen for 20% causes.

Root Cause Analysis

Root cause analysis is a problem-solving tool, works by identifying by problems, used by employees of manufacturing and work to solve. Root cause analysis is the best way to solve garments defects.

You may love to read this

Reducing sewing defects through root cause analysis

Continuous Flow

Continuous flow means running, moving or producing product continuously of every piece from raw material to finished product, not batch-wise production, called    “1-piece flow”.

Right First Time (RFT)

RFT is quality improvement tools, very much important apparel industry; every section has a target to achieve certain RFT level.

Please read this article to know details about it  RFT factors and calculation in Garments industry

A3 Problem Solving

A3 is a problem-solving tool, a challenge is to write explanation and solution in one page.The purpose of A3 tools is to analysis problem with root cause and define a direct solution.

PDCA

PDCA is plan-do-check-act or plan-do-check-adjust, 4 step management method for quality controlling and continuous improvement.

Overall Equipment Effectiveness (OEE)

Overall Equipment Effectiveness (OEE) means everything is productive in the manufacturing industry. OEE 100% mean manufacturing factory is fully productive, produce only good parts, no idle process, on the machine or other downtimes. If your factory OEE is 50%, surely their lots of things you have to improve and huge opportunity to develop.

Standardized Work

Standardized work is the most powerful lean tools by documenting the current best practice, the baseline for kaizen or continuous improvement. As the standard is improved, the new standard becomes the baseline for further improvements, and so on. Improving standardized work is a never-ending process.

Standardized work consists of three elements:

  1. Takt time, which is the rate at which products must be made in a process to meet customer demand.
  2. The precise work sequence in which an operator performs tasks within takt time.
  3. The standard inventory, including units in machines, required to keep the process operating smoothly.

You may love to read this Standardization of Apparel Manufacturing Industry

Poka-yoke (Mistake Proofing)

Poka-yoke is mistake-proofing tools which help to eliminate mistake in manufacturing floor, a quality control technique.

Cellular Manufacturing

Cellular manufacturing is manufacturing same types of product in cell which improve productivity and quality.

Total Productive Maintenance (TPM)

Total productive maintenance (TPM) is developed in 1960 based on 5S for effective machine and equipment to maximize operational efficiency increment.

Zero Quality Defects

Zero quality defects are the process of maintaining zero defects production through 100% inspection.

Lean Six Sigma certification courses

There are many institutions around the world that have Lean Six Sigma certification courses also available online courses to learn Lean Sigma and getting a certificate.

This content also refers below point’s information

  • Application of lean manufacturing tools in the apparel industry
  • Lean Manufacturing Techniques for garments
  • Importance of lean manufacturing in the apparel industry
  • Lean management in a garments factory
  • 5 Principles of lean manufacturing
  • Importance of lean manufacturing
  • Lean process improvement in Garments
  • List of lean manufacturing tools
  • The lean management system in the apparel industry
  • Lean concepts for garments manufacturing
  • Lean production in Garments manufacturing
  • Lean for garments manufacturers
  • Continuous quality improvement in the apparel industry
  • Application of Kaizen in Garments

Related articles you may love to read

Written by

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

Linkedin: A.M. Amirul Islam

Best Practice of Garments Washing Factory

Best Practice of Garments Washing Factory in Apparel Industry

The best practice is a manufacturing methodology or technique which is developed by longtime research and accepted as the best method to do a particular job. Here I am giving best practice followed by Garments washing factory, you may set them as a standard operating procedure (SOP) for the whole washing process. Hope this article would help you enrich your knowledge of best practices of Garments Washing Factory.

Best Practice of Garments Washing Factory Commonly Used

Pre-Production /Sample Development Stage of Garments Washing Factory

  1. Set a detailed SOP for sample development and pre-production procedure and team organogram for proceedings, make visible for all.
  2. Your factory should have a separate department or a team (R&D) for handling samples development and duplication.
  3. Development samples, and then duplicated samples are kept with records/recipe for future follow up.
  4. Development team reviews the PDM & check requirements before start shade band/the first batch.
  5. Developments samples are scan and reviewed by supervisor/manager before submitting for approval to buying-house.
  6. Trims and Leather patches being reviewed/Wash standard Checked prior to development.
  7. Risk Analysis meeting is to be held in factory or vendor to take necessary precautions before bulk & maintain the records.
  8. Washing recipes are set with record according to approved samples/standards/recipe/work order.
  9. Samples are reviewed under lightbox in dark room with identified light sources from an individual customer for color matching.
  10. Shade blankets/Shrinkage test done properly as per Wash standard.
  11. Always run a 1st batch trial and review it in detail, for measurements, appearance & shade, before running bulk production. Make a detailed report.
Garments Washing Machine, Modern Garments Washing Machine

Production Control -Dry and Wet process in Garments Washing Factory

  1. Inspecting Garments in before wash stage to check part shading, work hole, spot and shade segregation.
  2. Approved samples for each dry process available (with date & signature) and posted in front of the operator.
  3. Inspection procedure by AQL check for defects, keeping a daily updated report of pcs checked & defects found, use min 1,000 lux illumination, proper records kept before proceeding to next process.
  4. Quality Improvement efforts with Quality meetings, Defects Summaries, Pareto Analysis and Follow up. Use statistical data, to analyze quality results & make decisions to improve it. Review results & plan future corrective actions based on root cause analysis (should be visible in production lines), Pareto graph and follow up on top 5 defects. Compare results by day, week, month and by-line, section, dept., etc. You need to also keep track of the progress of at least 1 most recurring defect
  5. First bulk lot procedure is available in wash plant with a color-coding system.
  6. Garments are properly prepared and weighed/load size accordingly to suit for machine sizes and work order prepared.
  7. Approved recipe are properly prepared and posted for operators guide on each particular finish/machine.
  8. Garments are checked for scratch, color matched to standard before applying next step of wash/soften bath.
  9. You should have an in-house lab testing room, important Lab testing carried out at internal Lab e.g.: pH /tearing/washing fastness/crocking etc.
  10. Washing standards and shade bands available for each style/color and stored properly by dark ploy in a locked box.
  11. Measurements checked on every batch before and after washing, using a correct ruler and calibrated tape measurement and reported.
  12. The implementation of Preventive Maintenance system to reduce machine downtime and maximize machine fitness.
  13. Color evaluation Lab is maintained with buying house standard light source, CWF & D65 preferable.
  14. Implement 5’s method as a base to implement lean procedures. Must do weekly 5’s audits, give & post rating to each area. Do formal training & keep training records.
  15. Set up ETP and WTP to remove effluent from water and processing wastewater.
After Washing Garments Dryer Machine

Chemicals/ Dyestuff Control and Storage in Garments Factory

  1. Set a detailed SOP on chemical storage, dispatching and chemical handling safety procedure to visualize in floor.
  2. Temperature and humidity control, Storage area ventilation and floor set in good condition.
  3. All containers, big & small must be properly labeled to indicate which chemical they contain.
  4. Chemicals arrangement in good condition to avoid accidental/hazardous/inflammable mixing.
  5. Keep a log of chemicals dispatched to bulk production, quantity & chemicals specs must match washing recipe.
  6. RSL, MRSL reports must be handily available on site for each chemical. GOTS certificate, MSD and TDS documents should have in chemical and Dyestuff store.
  7. Warnings signs are posted on shelf or wall for, specially chemicals in storage.
  8. Dispensers are properly labeled for separate application to avoid chemicals Contamination.
  9. Weight machine or digital balance in use, Scales must be calibrated for accuracy.
  10. Chemicals are well prepared and weighted in advance for bulk production load.
  11. Stockkeeper in control of chemicals used.
  12. Chemical are labeled to containers/bags of purchase date or expiry date.

Technical requirement of cutting and Fabrics

  1. Garments dry process and wet process procedures
  2. Garments washing procedure
  3. Garments washing best practice
  4. Benchmarking Garments washing.
  5. Technical Requirement of Cutting and Fabrics

Written by

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

Linkedin: A.M. Amirul Islam

Merchandising Duties and Responsibilities in Garments Factory

Merchandising Duties and Responsibilities in Garments Factory

Merchandising plays the most important role in the apparel industry, merchandising general procedures are sourcing garments order, making a sample, price negotiation, price confirmation, order confirmation, fabrics-trims, and accessories booking, Fabrics-trims and accessories in-house and arrange QC file. Merchandising fills up the gap between garments manufacturer and buyer. So, if you are a stakeholder of the apparel industry then you must have the idea of merchandising duties and responsibilities in garments factory.

Job Description of a Merchandiser

This article is all about merchandising job description what a merchandiser does in garments factory as a senior merchandiser or merchandising manager, clearly described product development to shipment process in below. Hope this article would help you to clarify about merchandising job responsibility in the apparel industry.

Merchandising Duties and Responsibilities in Garments Factory

24 Merchandising Duties and Job Responsibilities in the Apparel Industry

  1. Product development and price offer to the client.
  2. Price confirms with the client and provides PI to the client for master L/C.
  3. Within a short time to collect all order concern document to the buyer for necessary action.
  4. Collect PI for open BTB L/C to arrange the all related materials.
  5. To follow-up T & A on regular basis to ensure on-time delivery with right quality and quantity.
  6. Lab dip, trims, bulk fabric color, and quality submit to the buyer for approval.
  7. Arrange all materials to make the required
  8. Closely monitoring sampling approval process and on time provide to the client for approval and arrange approval for the go ahead.
  9. Critical path analyzes and meeting with the buyer.
  10. PP meeting with the buyer.
  11. Size set submits to the buyer and arranges approval for bulk production.
  12. To in-house require materials on time to production according to T & A.
  13. To collect an inventory report from the store.
  14. Update factory production and the quality team about every message of buying a house
  15. Sent the require materials (trims, fabric, etc.) third-party test and provide the report to the client.
  16. Regular basis check with quality department and make ensure for correct quality.
  17. Make a schedule for inspection with buyer inspection team.
  18. Space booking to shipping line and goods handover on time.
  19. Confirm on time and smooth shipment to the buyer
  20. If in case fail on-time delivery or correct quality than make a decision and discuss with the head of department or high authority and finalized.
  21. Time to time reporting to the head of the department
  22. Reporting to the high authority in need basis.
  23. Send document for issue inspection certificate.
  24. If in case need than follow up payment issue.

Merchandising Duties and Responsibilities in Garments Factory pdf

Written by

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

Linkedin: A.M. Amirul Islam

Standard Minute Value: SMV in Garments, Calculation, Importance

Standard Minute Value: SMV in Garments, Calculation, Importance

The term Standard Minute Value – SMV is mostly used in the garments industry and it is common measurement calculated by the Industrial Engineer. Generally, SMV indicates the time taken to make garments by the workers using the right types of machinery. In garments factory, you may find that many people used to the SAM – Standard Allowed Minute which is same as SMV. SMV varies garments to garments, style to style, factory to factory. Management and buyers ask for SMV and it is the responsibility of the IE department to calculate SMV and give it to the respective parties. Here in this article, I will share details of Standard Minute Value: SMV in Garments, Calculation, Importance with a practical example.

Industrial Engineering is concerned with the design, improvement, and installation of an integrated system of men, machinery, and materials. SMV is one of the most important tools used by IE.

Standard Minute Value - SMV in Garments, Calculation, Importance

The prime objective of industrial engineering is:

  • To Increase Productivity
  • To eliminate waste and non-value added activities
  • To come up with the optimum use of scarce resources that would bring out the best results.

Importance of SMV in the Apparel Industry

The reason Why we use SMV in Garments Factory is given below

  • SMV is calculated for doing costing of garments
  • It is used for calculation of target and set the right target
  • For Calculating Efficiency of workers
  • SMV is calculated for making a plan and take effective factory production decision.

For Calculating SMV – Standard Minute Value in Garments you must have a proper idea of machine operating procedure and working process of workers. Close observation of Industrial Engineer is required to calculate the right SMV for a particular product or style in your factory.

Basically, SMV is the sum of the basic time requirement and allowance applicable to it. Normally allowance is given at the rate of 10% based on the efficiency.

Formulas of Calculating SMV

SMV in Garments Formula

Calculation of SMV in Garments

SMV = (Basic Time + Allocated Allowance)

The formula of Basic Time = Observe Time x Rating Factor

Basic Time: Basic time is the most likely time required to make garments considering observe time and applicable rating factors.

Observe Time: Time taken to do a work when an observer is observing closely and record the worker’s work speed.

Calculation of Observe Time = Total Cycle Time is divided by Number of Cycle

Cycle Time: Cycle Time is the time between starting a garments manufacturing and finishing of those garments.

Rating Factor: Rating factor is assigned based on an evaluation of worker performance which is conducted through eye judgment. A worker can be fast, slow and rating is on a scale of 100% to lower.

Costing SMV is calculated for sending SMV information to buyers. Normally 5% additional time is added with the actual SMV.

Costing SMV = Actual SMV + (Actual SMV x 5%)

Example of Calculation of SMV in Garments

Suppose for making a product the following assumption is there

  • Observe Time = 25 Minutes
  • Rating of Operator = 80%
  • Considering Allowance = 10%

Basic Time = 25minutes x 80% = 20 minutes

Allowance = 20 x 10% = 2 Minute

So, SMV = 20 minutes + 2 minutes = 22 minutes for making a particular garments product

Calculation of Capacity of Single Operator in Garments

  • If an operator works for 10 Hours a day
  • 30 minutes to make a product

Capacity = (1 operator x 10 hours x 60 minutes)/30 Minutes = 20 Pieces of Garments by an operator

If you assign 100 operators then your capacity will be = 100 operators x 20 pieces = 2000 pieces a day

Calculation of Efficiency Percent

  • SMV 22 Minutes
  • Working Hours 10 a Day
  • Number of Operators 100 person
  • Actual Production 2000 pieces

Efficiency (%) = (2000 pieces x 22 minute)/(100 operators x 10 hours x 60 minutes) x 100 = 73.33%

whereas the target was,

Target = (10 hours x 60 minutes x 100 operators)/smv 22 minutes = 2727 Pieces of garments

SMV of Different Types of Garments Manufacturing

Hopefully, you understand what is Standard Minute Value: SMV in Garments, Calculation, Importance of SMV in the apparel industry. If you have any confusion then please let me know. I will try to clarify farther in details.

Written by

Md. Nahian Mahmud Shaikat

Costing Sheet of Garments Manufacturing

Costing Sheet of Garments Manufacturing

Woven Garments Costing Sheet: Do necessary costing before taking Garments orders because costing very important work for garments merchandising. This article has three types of garments costing, include all trims and accessories costing and fabrics costing. Here costing given per pcs wise and dozen wise for your easy understanding. Hopefully, after seeing this you will have a good idea of costing sheet of garments manufacturing.

Costing Sheet of Garments Manufacturing

Costing Sheet of kids Trouser

Costing Sheet of Kids Trouser
FABRICS DETAILS: 73% cotton, 25% poly, 2% elastane denim 7.5 oZ (YR-1923/3)
Sl No. Particulars COST SHEET FOR PER PCS+DZN
YY/YDS PRICE/YDS COST/PCS COST IN DZN
1 Self Fabric 1.2 $1.85 $2.22 $26.64
Total Fabrics Cost- $2.22 $26.64
Basic Trims
2 Pocketing 0.15 $0.70 $0.11 $1.26
3 Interlining $0.03 $0.36
4 Metal Zipper $0.12 $1.44
5 Plastic Button $0.02 $0.24
6 Metal button $0.04 $0.48
7 Metal Rivet $0.05 $0.60
8 Thread $0.08 $0.96
9 Hole elastic $0.06 $0.72
10 String with plastic tipping  $                 –
11 Special label EF, Yigga girls+SIZE WOVEN $0.03 $0.36
12 WASH CARE LABEL (LEFT SS INSIDE) $0.03 $0.36
13 WASH CARE LABEL (UNDER WCL1) $0.03 $0.36
14 HANG TAG EF, Yigga girls $0.04 $0.48
15 PRICE STICKER $0.01 $0.12
16 Waist tag (double) $0.08 $0.96
17 EMBROIDERY $0.10 $1.20
18 String $0.03 $0.36
19 Poly $0.08 $0.96
20 Carton $0.07 $0.84
21 Carto STKR,Tagpin,Gumtape $0.06 $0.72
Total- $1.07 $12.78
Embroidery/Print  $                 –
Total-  $                     –  $                 –
Wash  TOWEL BEACH WITH/PP $0.75 $9.00
Total- $0.75 $9.00
ALL FABRICS+TRIMS COST $4.04
Commercial Cost $0.08 $0.97
CM $1.35 $16.20
Total- $1.35 $16.20
EXTRA- $0.03
FINAL FOB: $5.50 $65.90

Costing Sheet of Skinny Fit Denim Pants

Costing Sheet of Skinny Fit Denim Pants
DATE : 1-Jan-19 SIZE RANGE : 38-50
BUYER : ORD/QTY : 5500 pcs
STYLE/REF NO : UNIT PRICE : $8.00
P.O. NO : TOTAL VALUE : $44,000.00
ITEM DESC  : SKINNY fit DENIM DELIVERY DATE  :  
SL ITEM PARTICULARS QTY DZ U/PIECE TOTAL  
COST/DZ
FABRIC 66% cotton 32% POLY 2% Lycra. Cuttable Width:53″(Shrinkage:L-4%, W-16%) 15.75 YDS  $ 2.51 $ $39.53
Pocketing Sheeting pocketing WHITE + BLACK 4.8 YDS  $ 0.9 $ $4.32
INTERLINING TC INTERLINING 2.2 YDS  $ 0.1 $ $0.22
TOTAL COST OF FABRIC $ $44.07
TOTAL ACCESSORIES 1 dz  $ 15.26  $ 15.26
 WASH COST (tei, whisker, hands and, pp, ) 1 dz  $ 7  $ 7
PRINT COST 1 dz  $ 3  $ 3
EMB COST 1 dz  $ 1.5  $ 1.5
 $  $ 70.83
CUTTING & MAKING  ( CM ) COST 1 dz  $ 18  $ 18
 $  $ 88.83
COMM  COST 1 dz  $ 2.12  $ 2.12
COMMISION 1 dz  $ 1  $ 1
company profit 1 dz  $ 4  $ 4
FOB PER DOZEN 1 dz  $  $ 95.96
PRICE PER PC 1 pcs  $  $ 8 12
1 pcs  $  $ 8 FOB $ PCS
TOTAL ACCESSORIES DETAILS COST
Wash Care label 1.05 DZ  $ 0.12 $ 0.13
Care label 1.05 DZ  $ 0.08 $ 0.08
 Label 1.05 DZ  $ 0.7 $ 0.74
Antitheft 1.05 DZ  $ 0.6 $ 0.63
Back Pocket card 1.05 DZ  $ 0.4 $ 0.42
TAPE 8 YDS  $ 0.1 $ 0.8
Waist Tag 1.05 DZ  $ 0.25 $ 0.26
HANG TAG-1 1.05 DZ  $ 0.5 $ 0.53
HANG TAG-2 1.05 DZ  $ 0.5 $ 0.53
Patch 1.05 DZ  $ 0.7 $ 0.74
Barcode sticker poly 1.05 DZ  $ 0.3 $ 0.32
Sticker tag 1.05 dz  $ 0.2 $ 0.21
Zipper 1.05 dz  $ 1.5 $ 1.58
Button 0.09 grs  $ 6.2 $ 0.56
Rivet 0.55 grs  $ 2.1 $ 1.16
tissue paper 1.05 dzn  $ 1 $ 1.05
POLY BAG BLISTER 1.05 DZ  $ 0.3 0.32
POLY BAG PE 10mm 1.05 DZ  $ 1.6 $ 1.68
THREAD 20/4 – 1500 mtr 0.7 con  $ 0.8 $ 0.56
40/2 0.75 con  $ 0.72 $ 0.54
20/2 – 3000mtr 0.65 con  $ 0.78 $ 0.51
GUM TAPE 1.05 ROL 0.5 $ 0.53
SCOTCH TAPE ROL $
TAG PIN BOX $
Shipping mark 1.05 PC  $ 0.06 $ 0.06
CARTON 7 PLY 1.05 PC  $ 1.3 $ 1.37
COST OF TRIMS/ACCESSORIES $ 15.26

Costing Sheet of Skinny Fit Denim Pant

Costing Sheet of 5 Pockets Long Pant

Costing Sheet of 5 Pockets Long Pant
DATE : 1-Jan-19 SIZE RANGE : 44-58
BUYER : ORD/QTY : 9500 pcs
STYLE/REF NO : UNIT PRICE :
P.O. NO : TOTAL VALUE :  $                                  –
ITEM DESC : 5 PKT LONG DELIVERY DATE : TBA
SL ITEM PARTICULARS QTY DZ U/PIECE TOTAL  
COST/DZ
FABRIC 98% Cotton 2% Spandex,2/1 “S” Twill, Non-Peach Finish. Cons: 30x3Gr40D/170×80 Width: 5l”/52” 21.2 YDS  $ 2.38 $ $50.46
Pocketing Sheeting pocketing (White) 4 YDS  $ 0.75 $ $3.00
INTERLINING TC INTERLINING 2 YDS  $ 0.1 $ $0.20
TOTAL COST OF FABRIC $ $53.66
TOTAL ACCESSORIES 1 dz  $ 15.66  $ 15.66
 WASH COST (ENZYME WASH WITH SILICONE) 1 dz  $ 2  $ 2
PRINT COST 1 dz  $  $ 0
EMB COST 1 dz  $  $ 0
 $  $ 71.31
CUTTING & MAKING  ( CM ) COST 1 dz  $ 15  $ 15
 $  $ 86.31
COMM  COST 1 dz  $ 1.07  $ 1.07
COMMISSION 1 dz  $  $ 0
company profit 1 dz  $ 5  $ 5
FOB PER DOZEN 1 dz  $  $ 92.38
PRICE PER PC 1 pcs  $  $ 7.7 12
1 pcs  $  $ 7.7 FOB $ PCS
TOTAL ACCESSORIES DETAILS COST
Wash Care label 1.05 DZ  $ 0.1 $ 0.11
Care label 1.05 DZ  $ 0.1 $ 0.11
Satin Label 1.05 DZ  $ 0.1 $ 0.11
Sccurity Label 1.05 DZ  $ 0.8 $ 0.84
Main Label,Size Label, Fit Label, Brand Label Loop Label 1.05 DZ  $ 0.75 $ 0.79
Twill Tape 1.05 DZ  $ 0.66 $ 0.69
Pocket Flasher 1.05 DZ  $ 0.36 $ 0.38
Waist Tag 1.05 DZ  $ 0.55 $ 0.58
HANG TAG-1 1.05 DZ  $ 0.7 $ 0.74
HANG TAG-2 1.05 DZ  $ 0.7 $ 0.74
Disclimar Tag 1.05 DZ  $ 0.55 $ 0.58
Patch 1.05 DZ  $ 2 $ 2.1
Barcode sticker poly 1.05 DZ  $ 0.2 $ 0.21
Sticker tag 1.05 dz  $ 0.15 $ 0.16
Zipper 1.05 dz  $ 1.4 $ 1.47
Button 0.08 grs  $ 6 $ 0.48
Rivet 0.18 grs  $ 2.5 $ 0.45
tissue paper 1.05 dzn  $ 0.65 $ 0.68
POLY BAG BLISTER 1.05 DZ  $ 0.3 0.32
POLY BAG PE 10mm 1.05 DZ  $ 0.65 $ 0.68
THREAD 20/4 – 1500 mtr 0.75 con  $ 0.76 $ 0.57
40/2 0.75 con  $ 0.63 $ 0.47
20/2 – 3000mtr 0.65 con  $ 0.73 $ 0.47
GUM TAPE 1.05 ROL 0.6 $ 0.63
SCOTCH TAPE ROL $
TAG PIN BOX $
Shipping mark 1.05 PC  $ 0.06 $ 0.06
CARTON 7 PLY 1.05 PC  $ 1.2 $ 1.26
COST OF TRIMS/ACCESSORIES $ 15.66

Costing Sheet of 5 Pockets Long Pant

Download excel Sheet of Garments Costing Sheet

This content also refers below information

  • Costing of Woven Garments
  • Costing of woven bottom Garments
  • Costing of woven trouser
  • Costing of basic 5 pkts long pant
  • Costing of Ladies skinny denim pant
  • Clothing manufacturer cost sheet
  • Garments costing
  • How to make costing sheet of woven garments?

Written by

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

Linkedin: A.M. Amirul Islam

Operation Breakdown, SMV and Layout of Blouse Manufacturing

Operation Breakdown, SMV and Layout of Blouse Manufacturing

A blouse is worn by the women in South Asian, it is worn in the upper part of a body. As per this sewing operation bulletin, total SMV is 4.73 and 25 sewing machine will be needed. Here also available downloadable excel sheet for your clarification. Hopefully, after reading this you will have a good idea of Operation Breakdown, SMV and Layout of Blouse Manufacturing.

Operation Breakdown, SMV and Layout of Blouse Manufacturing
NO OPERATION M/C Type Attach. M/C TGT MAN LAY
Foots S.M.V LVL OUT
FRONT PART
1 Front Two part O/L 3T O/L 0.1 600 0.53 1
2 Front two-part joint S/N 0.15 400 0.79 0.5
3 Btn placket making mark & Make S/N 0.25 240 1.32 1
4 Ticken Mark at back part Helper 0.15 400 0.79 1
5 Ticken tack at back part S/N 0.16 375 0.85 1
6 Solder joint 5T O/L 0.15 400 0.79 1
7 Slv rolling S/N 0.25 240 1.32 1
8 Slv joint 5T O/L 0.3 200 1.59 2
9 Side joint 5T O/L 0.2 300 1.06 1
10 Hanger loop, Btn loop measure & Cut Helper 0.22 273 1.16 1
11 Hanger loop tack S/N 0.15 400 0.79 1
12 Btn loop Make & joint S/N 0.2 300 1.06 1
13 Neck tape joint with body S/N 0.45 133 2.38 2
14 Neck top stt. S/N 0.35 171 1.85 2
15 Front Hem tape joint with body S/N 0.5 120 2.64 3
16 Back Hem tape joint with body S/N 0.3 200 1.59 2
17 Back Hem tape Top stt. S/N 0.2 300 1.06 1
18 Front Hem tape Top stt. S/N 0.45 133 2.38 2
19 Tack at underarm S/N 0.1 600 0.53 0.5
20 Main lbl joint S/N 0.1 600 0.53 0.5
TOTAL     4.73 0.19 25 25
  GRAND TOTAL     4.73 0.19 25 25

Summary of Sewing Operation Bulletin of  Blouse Manufacturing

Man & M/C REQUIREMENT
NO MACHINE TYPE REQ
1 S/N 18
2 D/N
3 O/L
4 3T O/L 1
5 4T O/L
6 5T O/L 4
7 2T F/L (Chain)
8 Button Attach
9  F/L
10 F/O/A
11 Ironman
12 Helper 2
13 Chain stc
14 O/L (Chain)
15 Buttonhole
16 KANSAI
TOTAL 25

Here,

  • S/N Single needle lock stitch
  • D/N Double needle lock stitch
  • O/L Overlock machine
  • 3T O/L 3 Thread overlock machine
  • 4T O/L 4 Thread overlock machine
  • 5T O/L 5Thread overlock machine
  • F/L Flat Lock machine
  • F/O/A Feed of the arm

Operation Breakdown, SMV and Layout of Blouse Manufacturing

Blouse Operation Bulletin (excel)

Written by

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

Linkedin: A.M. Amirul Islam

What is RFT, RFT Factors and Calculation in Apparel Industry

What does Right First Time (RFT) Mean?

Right First Time is lean tools that mean doing the thing right in the first time which can remove eliminate or repair and defects producing in garments manufacturing. RFT percent is one of the key performance indicator tools in Garments quality control. In this article, we will discuss What is RFT, RFT Factors and Calculation in Apparel Industry.

What is RFT, RFT Factors and Calculation in Apparel Industry

What is RFT, RFT Factors and Calculation in Apparel Industry

Advantages/Benefits/Importance of Producing Right the First time

  1. Reduce cost and penalty of quality failure
  2. Improve quality and productivity
  3. Remove re-work and repairing
  4. Save time and energy
  5. Save defects rectification cost
  6. Improve work accuracy

RFT calculation for Cutting, sewing, finishing, and Quality Control

Right First Time = (Number of passed goods or Lot / Number of total produced Garments or Lot) x 100

For example, If 200 pcs Garments is produced in the sewing section, found 13 pcs defect by QC then first pass quantity is =(200-13)= 187 pcs.

So, Sewing RFT will be = (187/200*100) % = 93.5%

Date RFT Defect %
4/11/2017 95.67% 4.33%
5/11/2017 96.54% 3.46%
6/11/2017 96.57% 3.43%
7/11/2017 95.80% 4.20%
8/11/2017 96.20% 3.80%
9/11/2017 96.74% 3.26%

Actual and Target RFT

Date Actual RFT Target RFT Total Check Quantity
1-Jul 93.40% 96% 2500
2-Jul 93.50% 96% 2600
3-Jul 93.10% 96% 2400
4-Jul 94.20% 96% 3000
5-Jul 94.60% 96% 3500
6-Jul 93.50% 96% 2500

RFT Key Factor Areas of Garments Manufacturing

There may have others area you need to count RFT, I am giving here what I know. Surely RFT is a performance measuring tool of quality control.

  1. Cutting panels quality
  2. Sewing output garments quality
  3. Finishing packed garments quality
  4. Final Audit RFT.

Written by

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

Linkedin: A.M. Amirul Islam

Operation Breakdown, SMV and Layout of Jacket Manufacturing

Operation Breakdown, SMV and Layout of Jacket Manufacturing

A jacket is not an easy product to produce in sewing section, lots of complex operation in it.  As per this Operation bulletin total SMV is 44.97, 73 sewing machines needed and manpower should be 75. This content would help you to know about Operation breakdown, SMV and Layout of woven Jacket manufacturing of sewing what given in below. In this article, we are going to share details of Operation Breakdown, SMV and Layout of Jacket Manufacturing.

Operation Breakdown, SMV and Layout of Jacket Manufacturing

Operation Breakdown, SMV and Layout of Jacket Manufacturing1

Operation Breakdown, SMV and Layout of Jacket Manufacturing
NO OPERATION M/C Type Attachments M/C TGT MAN LAY Seam Length
Foots S.M.V LVL OUT
HOOD               
1 Hood panel joint (shell) S/N 0.8 75 1.33 1
2 Hood panel 1/4 T/S D/N 0.75 80 1.25 1
3 Inner side Hood panel joint(sherpa) S/N 0.7 86 1.17 1
4 Facing jnt with lining psn at hood mouth opening S/N 0.9 67 1.5 1
5 Hood mouth opening ruling S/N 0.5 120 0.83 1
6 Hood placket mark for make & decoration Helper 0.9 67 1.5 1
7 Hood placket  make & decoration S/T S/N 0.85 71 1.42 1
8 Hood mark for 4 points snap button attach Helper 0.4 150 0.67 1
9 Hood mouth opening 1/16 T/S S/N 0.7 86 1.17 1
10 Hood eye hole 2 points for dawcode insert Buttonhole 0.55 109 0.92 1
Front & back part lining              
11 Lining 2 part middle joint S/N 0.65 92 1.08 1
12 Hanger loop make & joint at back neck S/N 0.5 120 0.83 1
13 Patch label iron & Bon Fusing IRON 0.8 75 1.33 1
14 Lining back yoke joint S/N 0.7 86 1.17 1
15 Patch & main label joint S/N 0.95 63 1.58 2
16 Inner chest pocket & side H/pocket facing joint S/N 0.6 100 1 0.5
17 Inner chest pkt bone mark Helper 0.35 171 0.58 0.5
18 Inner chest pkt bone make D/N 0.35 171 0.58 1
19 Inner chest pkt  bone cutt & turn Helper 0.35 171 0.58 1
20 Inner chest pkt bone 1/16 T/S (upper & lower) S/N 0.75 80 1.25 1
21 Inner front panel joint S/N 0.85 71 1.42 1
22 Inner front panel 1/16 T/S S/N 0.9 67 1.5 0.5
23 Lining sleeve panel joint S/N 0.75 80 1.25 0.5
Front part (shell)              
24 Front side H/pocket Mark & bone mark for snp btn attach Helper 0.5 120 0.83 1
25 Front side H/pocket bone make D/N 0.8 75 1.33 1
26 Front H/pkt bone cutt& turn Helper 0.75 1 1.25 1
27 Front H/pkt bone 1/16 T/S (upper) S/N 0.6 100 1 2
28 Front H/pkt bone 1/16 T/S (Lower) S/N 0.6 100 1 1
29 Front  H/pkt bone decoration S/T S/N 0.55 109 0.92 1
30 Twill tap joint chest & waist psn S/N 0.85 71 1.42 1
31 Shoulder tap & slv cuff tap iron IRON 0.5 120 0.83 1
32 shoulder tap & slv cuff tap make & 1/16 T/S S/N 0.07 857 0.12 1
34 Shoulder jnt & tap jnt with shoulder psn S/N 0.5 120 0.83 1
Back part shell              
35 Back part middle 2 part joint S/N 0.85 71 1.42 1
36 Back part middle 2 part 1/16 T/S S/N 1 60 1.67 2
37 Faching jnt at wist psn ( inside) D/N 0.6 100 1 1
38 Faching attach at bk lower middle psn S/N 0.4 150 0.67 1
Assembly part              
39 Shoulder jnt (Lining) S/N 0.4 150 0.67 1
40 Sleeve jnt (Lininig) S/N 0.8 75 1.33 1
41 Side seam jnt (Lining) S/N 0.9 67 1.5 1
42 Sleeve panel jnt (Shell) S/N 1 60 1.67 2
43 Sleeve panel 1/16 T/S (shell) S/N 1 60 1.67 2
44 Sleeve jnt (Shell) S/N 0.85 71 1.42 1
45 Armhole 1/4 T/S D/N 0.8 75 1.33 1
46 Hood joint S/N 1 60 1.67 2
47 Hood neck 1/16 T/S S/N 0.75 80 1.25 1
48 Side joint (Shell) S/N 0.9 67 1.5 2
49 Placket mark Helper 0.6 100 1 2
50 Placket make & 1/16 T/S S/N 0.9 67 1.5 2
51 Placket with zipper jnt S/N 0.7 86 1.17 1
52 Zipper jnt (Right side) S/N 0.7 86 1.17 1
53 Zipper jnt (Left side) D/N 0.7 86 1.17 1
54 Mark for snp btn 18 points Helper 0.8 75 1.33 1
55 Punch &attach  for snp btn 18 points Button Attach 1 60 1.67 2
56 Sleeve cuff with elastick jnt S/N 0.6 100 1 1
57 Lining slv with cuff joint S/N 0.7 86 1.17 1
58 Sleeve mouth opening rulling S/N 0.6 100 1 1
59 Mark for grumet attach at front & bk mdl drawcode unsert psn Helper 0.5 120 0.83 1
60 Punch & attacg 4 points Grumet psn at waist SNAP BTN 0.6 100 1 1
61 Shell & lining joint with front opening psn ( right) S/N 0.75 80 1.25 1
62 Shell & lining joint with front opening psn ( Left) S/N 0.75 80 1.25 1
63 1/4 T/S psn at front opening psn S/N 0.7 86 1.17 1
64 Faching jnt with btm hem (insid) S/N 0.9 67 1.5 1
65 Back btm slit cut T/S S/N 0.45 133 0.75 1
66 Btm hem S/N 0.5 120 0.83 1
TOTAL     44.97 0.6 75 73

Summary of Operation bulletin, SMV and Layout of woven Jacket manufacturing

NO MACHINE TYPE REQ
1 S/N- Single needle lock stitch 52
2 D/N- Double needle lock stitch 6
3 O/L- Overlock machine
4 3T O/L- 3 thread Overlock machine
5 4T O/L- 4 thread Overlock machine
6 5T O/L- 5 thread Overlock machine
7 2T F/L (Chain)- Flat lock machine
8 Button Attach 2
9  F/L- Flat lock machine
10 F/O/A- Feed of the arm
11 IRON 2
12 Helper   10
13 Chain stc
14 O/L (Chain)
15 Button hole 1
16 SNAP BTN 1
17 KANSAI
TOTAL 73

Written by

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

Linkedin: A.M. Amirul Islam

Visual Management System in Apparel Industry

Visual Management System in Apparel Industry

Visual management is a part of lean manufacturing; an effective and standard method to communicate with every level of a factory with necessary information, a concept is to understand everything when a person visits manufacturing floor by visual data display system also include an important message for employees for learning, doing and achieve. Visualization boards applied in a factory for delivering information such as production status, production trend, Quality controlling status, delivery performance, and customer report. Visual controls are means, devices, or mechanisms that were designed to manage or control our operations (processes) so as to meet the purposes: informative, identification, instructional and planning. Here in this article, you will have an idea of what we can visualize, tools used, and advantages of Visual Management System in Apparel Industry.

Visual Management System in Apparel Industry

What are Generally Visualize in Garments Factory

  1. Hourly production board
  2. Efficiency graph, individual and line wise
  3. Quality DHU%, RFT
  4. Production and Quality target, Target vs Actual
  5. A counter sample for the sewing line
  6. Production Downtime & Performance Dashboard
  7. Delivery performance report
  8. All KPI reports
  9. Responsibilities of sewing operator
  10. Pareto analysis
  11. Kanban board
  12. Best sewing line names, best supervisors and operator
  13. Section wise safety assessment list and picture

Digital Visual Board in Garments Production Floor

 

List of Tools can be Used to Visualize Garments Factory

  1. Visual control boards
  2. Digital computerized board
  3. Visual workstation
  4. Signs, labels, name tags and direction
  5. Borders, lines; level scales
  6. Board, Shadow board, shadows, color codes and displays (i.e. Colour and shape)
  7. Graphs, info graph charts,
  8. Photos, films,
  9. Posters
  10. Mascots,
  11. Sketches
  12. Drawings
  13. Models
  14. Sticky
  15. Decision
  16. Trees,
  17. Kanban systems (cards, lights)

Advantages/ Benefits of Visualization in the Apparel Industry

  1. Increase effective communication and easy understanding for all
  2. For successful outcomes from the production floor
  3. Immediate assessment of the daily and weekly goals
  4. To motivate employees
  5. To familiarize or set the stage for a performance/event
  6. Absorb information quickly.
  7. Understand the next steps
  8. Share the insights with everyone
  9. It’s easy to understand and clarify
  10. Proper and regular updates
  11. Immediate Performance Information
  12. Evidence of actual achievement

This article also refers to

  • Visualize Garments factory
  • How to visualize Garments manufacturing key tools

Visual Management in the Apparel industry pdf

Written by

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

Linkedin: A.M. Amirul Islam