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 a 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 a regular basis to ensure on-time delivery with the 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 checks with the quality department and makes ensure for correct quality.
  17. Make a schedule for inspection with the buyer inspection team.
  18. Space booking to the 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 a document for an 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 a 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 a costing of garments
  • It is used for calculation of target and set the right target
  • For Calculating the 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

What is WIP, WIP Calculation, Reducing, Reporting in Garments Manufacturing

What is WIP, WIP Calculation, Reducing, Reporting in Garments Manufacturing

What is WIP? What does WIP mean in Apparel Industry? WIP means Work In-progress or In-process, an inventory system in the Garments manufacturing process in cutting, sewing and finishing but not for raw materials warehouse or finished goods warehouse. WIP for the manufacturing floor the quantity between input and output what backlogged in production. In this article we will see the details of What is WIP, WIP Calculation, Reducing, Reporting in Garments Manufacturing.

What is WIP, WIP Calculation, Reducing, Reporting in Garments Manufacturing

WIP Calculation of Cutting, sewing, Washing, and Finishing

  • Cutting WIP = Total cut quantity – Total quantity inputted to the sewing section

For example, Cutting section cut total 10,000 pieces for style# 5572819 and 7520 pieces have been inputted to the sewing department, then cutting room WIP will be =(10,000-7520) =2480 pieces.

  • Sewing Line WIP = Total pieces (GMTS Qty) inputted to the line – Total number of garments sewing output completed

For example, if a sewing Line totals 7520 pieces have been got input for style#5572819 and a total of 3500 pieces are produced from the line. Sewing line WIP is (7520-3500) = 4020 pieces.

Limiting washing WIP is very much important because most factories don’t have own washing facility. So they have to send Garments to another factory for washing. Delaying in washing can effect on time delivery.

  • Washing WIP= Total Garments sent to washing – Total Garments received from washing

Finishing, the last stage of Garments manufacturing, garments manufacturer challenge limiting washing and finishing WIP. Every factory especially follows up washing and finishing WIP to maintain on-time delivery to the customer.

  • Finishing sections WIP = Total Garments received from washing – Total packed quantity

WIP Report Format for the Apparel Industry

It is very easy reporting WIP, doesn’t need to make a format for checking WIP, you can keep WIP calculation in a production report. Here excel reporting format uploaded to download for all of you.

Cutting and Sewing WIP

Daily Production Report – Sewing
Line Name Style Order Quantity Al. Quantity Input Date Day Input Ttl Input Day Output Total Output Input Balance Output Balance Line WIP
A 808-8126 18211 19571 28-May-18 15401 1440 15300 4170 4271 101
A & B 808-8129 11897 12851 31-May-18 579 12413 1552 12407 438 444 6
B 834-4100 3000 3242 7-Jun-18 1263 3122 1208 2140 120 1102 982
C 808-2844 6570 6936 30-May-18 6714 925 6095 222 841 619
E 899-4241 30912 21278 22-May-18 2108 21278 1300 18330          – 2948 2,948
F 899-4241 30912 10444 4-Jun-18 2108 10444 1600 9590          – 854 854
G 808-8514 3060 3444 9-Jun-18 1099 305 305          –          – 794
H RM1005109 3202 3425 9-Jun-18 889 1996 600 600 1429 2825 1,396
I RM1020409 4115 4445 6-Jun-18 4384 1205 3540 61 905 844
J RM1020509 5854 6243 4-Jun-18 6174 1500 5961          –          – 213

Washing and Finishing WIP Report

Total Sent to Wash Day Receive from Wash Total Receive from Wash Work in Process in Wash
25401 7 25192 209
17234 61 17112 122
10082 54 10057 25
13065 33 13050 15
16154 44 16150 4
2173 82 2137 36
Total Wash Receive Day Poly Total Poly Poly Balance/Finishing WIP
79274 1200 3500 75774
19545 320 1850 17695
531 55 111 420
104 100 100 4
4664 1800 3855 809

Download WIP report format in excel chart

How to Limit excessive Work In-process (WIP) in Garments production Floor

  1. Reducing bottleneck and productivity improvement
  2. Adding machines and improving workforce
  3. Proper Layout and machine allocation
  4. Follow Kanban board in the production floor
  5. Keeping accurate production flow chart/ sequence
  6. Producing a good quality product and stopping re-work

Problems of Excessive WIP for Apparel Industry

  1. Transit areas become obstructed and blocked
  2. Garments gathering in the workplace
  3. Garments inadequate to maintain a good appearance
  4. Hamper normal production flow
  5. Poor housekeeping

This Content also has an answer of below points

  • How to find out WIP in the Apparel industry
  • Limiting WIP in the Apparel industry
  • WIP follow up in the Apparel industry
  • WIP calculation of Cutting
  • WIP calculation of Sewing
  • WIP calculation of Washing
  • WIP calculation of Finishing

Written by

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

Linkedin: A.M. Amirul Islam

Kanban Board in Garments Manufacturing Production Floor

Kanban Board in Garments Manufacturing Production Floor

What is Kanban? Kanban is a visual card or billboard; Japanese word which meaning Cards or board, a tool of lean manufacturing for visualization entire production teamwork to control production focusing on creating a production system more effective and efficient, focusing mainly in the production and logistics activities. Kanban is a visual system as ‘Signal card’ indicate what to do, items will put when needed, Kanban cards order necessary task, update with time and surely reduce wastage. In this article, you will have an idea of how kanban board in garments manufacturing production floor is used.

Kanban Board in Garments Manufacturing Production Floor

Types of Kanban System

Generally, two types of Kanbans or Kanban Cards used in the apparel industry:

Production Kanban

Production Kanban is the first step of Kanban implementation, production Kanban takes the place of standard production orders in material requirements planning (MRP) push.

Transportation Kanban

Transportation Kanban system is very important that carried on the trolley, containers that are associated with the transportation to move through the loop again.

Importance of Implementation Kanban Board in Apparel Industry

  1. Reduce idle time in a production process.
  2. Increase productivity, more effective and efficient production
  3. Visualize work and optimize the flow of the work
  4. Reduce WIP (Work in Process)
  5. Improve workflow
  6. Avoidance of over-production and limitation of stocks
  7. Higher availability of materials
  8. Reduce inventories
  9. Improve communication between management and operational staff

Garments Kanban Board Information Includes

  1. Backlog
  2. To do list
  3. Doing List/ work-in-process List
  4. Work completed List
  5. Plan list
  6. Lot name
  7. Process name

This content also have the answer of below points

  • Kanban system in Apparel manufacturing
  • Set up Kanban board in the production floor
  • Kanban board in sewing floor

If you have any confusion then please let me know.

Written by

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

Linkedin: A.M. Amirul Islam

Fabrics Warehouse and Cutting Section Best Practices in Apparel Industry

Fabrics warehouse and Cutting Section Best Practices in Apparel Industry

Garments best practice in Fabrics area and Cutting section: A best practice is a methodology, technique or system that has been accepted as superior to any alternatives because it produces best results that because it has become a standard way of doing things. This article includes two sections manufacturing best practice of garments manufacturing factory, sections activities are Fabrics preparatory procedures up to cutting and cutting procedures before cutting. Hopefully, after reading this article you will have a good idea of Fabrics Warehouse and Cutting Section Best Practices in Apparel Industry.

Best Manufacturing Practice for Fabrics Preparatory Procedure in a Garments Factory

There are lots of work needs to be done before cutting, fabrics inspection, shrinkage- distortion, color- shade control, etc. Here I am giving all procedure sequence wise in below.

A) Fabric Store

  • Space to keep a roll separately (E.g. Fabric roll on a rack)
  • Available space to keep head ends
  • Availability of pallets (suggested for plastic/non-wooden pallets) to keep fabrics roll
  • Good condition, ventilation store area, and keep a stack of fabric rolls prevent direct heat, sunlight/dust, etc. & humidity
  • Fabric rolls are stored as per shade group base on mill packing list/maker after wash blanket
  • Uses of Bin card mentioning style & shade name in a roll stack
  • Reporting of fabric roll keeping by log book in a soft or hard copy

B) Fabric Inspection

  • Availability of Lightbox/ Lightroom (Requirement CWF- 100 FCL)
  • Availability & sufficient no of Inspection m/c. sewing m/c, defect, display board, notice board
  • Availability of relaxation m/c. / area / racks
  • Record Fabric roll inspection report (covering packing lists from the supplier all shade groups in a blanket) & defect matrix

 C) Fabric Shade Group

  • Available of (2 sets) before wash & after wash Blanket preparation details and records
  • The proper size of shade blanket as per buyer requirement
  • Records & availability of color continuity card (after wash blanket)
  • Sufficient space for Blanket storage & easy excess

D) Shrinkage, Distortion, Skew test, CSV

  • Keeping records, test specimen & maintaining 100% shrinkage & distortion test procedures as per buyer Requirement for stretch fabric.
  • Keeping records, test specimen & maintaining 30% shrinkage & distortion test procedures as per buyer Requirement for non-stretch fabric.
  • Use of standard tools for marking & measuring shrinkage (AATCC 135) & distortion (AATCC 179 opt 1)
  • Maintaining conditioning & relaxation procedure before shrinkage measurement.
  • Keep a record for skew test
  • Maintaining CSV / SCS check on 100%  fabric roll from packing list (non-denim)

E) Operations

  • 5S implementation
  • Sufficient manpower
  • A computer for mail communication & data entry
  • Sufficient sewing m/c for a blanket & shade band making
  • Notice, SOP & defect display board
  • Defect analysis & Pareto analysis

Cutting Best Practice

Cutting is a sensitive process in garments manufacturing. Garments measurement and sewing depend on cutting accuracy. Here I am giving a checklist of the best cutting practice of apparel manufacturing, below data would help you to about cutting procedure best practice in apparel manufacturing.

Critical Path

  • Is the critical path system being followed?
  • Is there software used to create the critical path? (Provide the name of the software in the remarks column)
  • Is the pattern manipulation and marker ratio calculations done before Fabric is delivered?

Width Batching

  • Is the fabric width checked as per the A-Z manual for every roll?
  • Is the fabric width recorded and provided to the lay planning dept. with the shrinkage, shade and length reports?
  • Is the width batching report available?
  • Are new yield calculations done after the width batching? (Provide reports). Is the reason for the change in the yardage yield documented?

Length Confirmations

  • Are all the rolls checked for length and documented?
  • Is the fabric shortage addressed to the Purchasing Department?

Shrinkage and Shading

  • Are all the fabric rolls checked for the shading and records maintained?
  • Is the fabric shrinkage tested for each dye lot of the fabric and records maintained?
  • Is the A-Z manual fabric checking process followed for the shrinkage and shade checking?
  • Does the factory prepare an additional color continuity card?
  • Are the fabric shrinkage and shade SOP available and followed?

Fabric Relaxation

  • Is the fabric relaxed naturally and the relaxation time documented as per the customer manual?
  • Is the fabric relaxation historical data/information maintained and used for reference on actual relaxation for every type of fabric?
  • Is there a relaxation machine used for the fabric relaxation process?
  • Is relaxation report available?
  • Are the relaxed fabric rolls placed on shelves with one relaxed roll per shelf?
  • Is the fabric relaxed for a minimum of 24 hours before cutting? (48 hours minimum for Lycra/Elastane fabrics)

Lay Planning

  • Are leftover fabrics calculated in the MCR (Material Consumption report)
  • Is the balanced fabric documented and used for accounting in case of re-ordering?
  • Is the lay checked and approved by authorized personnel from Quality and technical
  • Are the lays planned as small size and big size combination until you derive at a single size marker, if not what is the alternate process?
  • Does the lay planner take into account the fabric inspection report details like shrinkage and shading; and width batching report
  • Is the marker consumption report for the projected calculation of yardage yield (YY) per piece documented?
  • Is the over-consumption calculated, and recorded?
  • Does the merchandising/planning dept. evaluate the Material over consumption and replenishment report for any over-consumption of the fabric.
  • Are the reports documented and maintained for easy retrieval?

Cutting Room

  • Does the cutting room request the fabric based on the Marker consumption report? (MCR)
  • Are the fabrics issued based on the PO and the BOM/MCR from the fabric store?
  • Is the additional fabric requirement informed and approved by the merchandiser and store?
  • Are the materials over consumption and replenishment guideline referred, for guidelines on reporting and requesting additional fabrics?
  • Are the over consumptions recorded and documented for the root cause analysis, to determine the cost of failure?
  • Is fabric held in the cutting room near the cutting table placed in the A-frames or Tracks in the appropriate manner?
  • All tables are clean underneath and have no redundant fabrics under the table or in contact with the floor at any given time.
  • Documentation and reports available

Spreading

  • Is there a spreading sheet used for every single layer in the cutting room?
  • Is the QA/Cutting Supervisor confirm, once the fabric is spread.
  • Is the visual fabric inspection done during spreading?
  • Are the separation papers used for the different colors in the same spread?
  • Is the spreading sheet maintained with all the details of the Roll of fabric to be used; and is the copy of the ticket that comes off the roll of fabric, attached to the spreading sheet.
  • Is marker Vs cut report prepared, to analyze the fabric consumption after cutting
  • Are spreading parameters set for the automated spreading machine
  • Is there a library of fabric tension for spreading available for future references?
  • Is the underlayer plain paper used for the manual cutting of the lay?
  • Is the perforated paper used for the automated cutting equipment of the lay?
  • Is end loss allowance of 1/2 inch (on either side) maintained in the lay during cutting?
  • Documentation and Reports available

Recuts

  • Are the re-cuts documented and recorded for further calculation of actual yardage yield, and assigned correct reason?
  • Is the T2’s performance analyzer
  • Are faults/errors identified and reduced with corrective action plans?
  • Documentation and Reports available

Issuance of cut goods

  • Is there an inward/outward procedure and format for the cut panels issued to the sewing section?
  • Is the sewing section in-charge know that the order is complete in terms of cutting, printing, embossing, embroidery or any other processes involved before sewing with the document?
  • Does the sewing section in-charge sign on receipt of the cut quantities taking control of the order quantity?

Fabric Returns

  • Is the left-over fabric returned to the store and documented daily?
  • Is the left-over fabric put back in the store/inventory for carryover orders?
  • Documentation and Reports available

Fabric Usage

  • Does the cutting room calculate the final yardage yield based on total fabric usage?
  • Are the following reports involved in deciding the final yardage yield usage, Marker Consumption Report (MCR); Marker Vs Spreading Report; Spreading Sheet; Re-cut quantities?
  • Documentation and Reports available

Key Performance Indicators

  • Does the process of ordering, have specific guidelines and measurable?
  • Does the factory maintain the records for 24months once the order is shipped?
  • Are the factory cutting room performance and efficiency calculated and documented?
  • Is the actual yardage yield calculated after an order has been shipped?

This Content Also Refers to

  • Good Practice for Garments Fabrics warehouse
  • Best Practice for Fabrics cutting process in Garments
  • Benchmarking Garments Fabrics warehouse
  • Benchmarking Fabrics cutting section

Fabrics Warehouse and Cutting Section Best Practices in Apparel Industry

Written by

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

Linkedin: A.M. Amirul Islam