Job Responsibilities and Report of Production Planning Department in Garments

Job Responsibilities and Report of Production Planning Department in Garments

PPC in Apparel Industry: PPC stands for production planning and control, planning for capacity utilization and on time raw material input, output and delivery. It helps a factory to utilize the resource allocation of activities, supply chain, materials, and production. A garments production planner plays a key role in Garments production, does line plan and execute planning. Here in this article, you will get detail ideas of Job Responsibilities and Report of Production Planning Department in Garments.

The Job Description of a Production Planner in the Apparel Industry

  1. Responsible to monitor and evaluate raw materials, manpower planning, production recording and follow up
  2. Production planning according to capacity and 100% capacity utilization in minimum cost.
  3. Setting production target and archive on time.
  4. Follow up sampling, pre-production activities, cutting, sewing, washing, and finishing according to plan.
  5. Update production planning time to time according to the current situation.
  6. Work to implement planning and reduce plan vs actual gap.
  7. Distribute production planning to all related production staff and meeting to implement planning.
  8. Monitor daily production; make daily production report and tracking section wise production.
  9. Achieve on time shipment maintaining production work sequence.
  10. Work with merchandising team to QC file as per production lead time and monitor trims-accessories and fabrics in-house status.
  11. Closely monitoring all pre-production activities(Size set cutting, PP meeting, Pilot Run) and priority-based work progressing.
  12. Chase finishing team for on-time final arrangement and ship the goods.
  13. Implement production planning and update time to time.

The Job Description of a Production Planner in the Apparel Industry

We have another article you may like: Production Planning and Control in the Apparel Industry

Planning Reports in Garments

Production planning department or planner has to send a planning report to mid and Top management. Here I am giving a planning report to understand how to make production planning report. Section wise production planning report is given in the below.

Line Wise Production Planning Report in Garments

Sewing Line Production Planning Report
Order No Input Date Planned Capacity / Day / Line No of Lines Name of line Working Hour/Day Production Unit Weekend / Holidays during prod No of Working Day Required Output Finish Date
8257873 7-Nov 800 1 2-C 10 MCL 2 8 17-Nov-18
825784 30-Oct 850 1 2-A 10 MCL 1 8 8-Nov-18
8257875 27-Oct 950 1 2-E 10 MCL 3 20 19-Nov-18

Report of Sewing Line Production Planning

Washing
Order No Wash Input Date Planned Capacity Per Day Production Unit No of Working Day Required Wash Will Complete
8257873 10-Nov-18 10000 MCL Laundry Ltd 9 20-Nov
8257874 8-Nov-18 10000 MCL Laundry Ltd 2 11-Nov
8257875 30-Oct-18 10000 MCL Laundry Ltd 19 21-Nov

Job responsibilities and Report of Production planning Department in Garments

Goods Finish To Final Audit
Order No Goods Finish Start Date Planned Capacity Per Day Weekend/Holiday during prod No of Working Day Required Goods Will Ready for Audit
8257873 3-Nov-18 10000 2 12 17-Nov-18
8257874 12-Nov-18 10000 1 7 20-Nov-18
8257875 11-Nov-18 10000 1 8 20-Nov-18
Plan Summary
Factory Wise Planned Production Capacity Sewing No Of line /Prod Unit Factory Wise Planned Production Capacity Wash A quantity of Dry Process / Normal Wash
12000 10 15000 NOT APPLICABLE
10500 10 15000 NOT APPLICABLE
9500 10 12000 NOT APPLICABLE

Line Plan of Garments

Line Plan of Garments
QTY Shipment CRD Input date Sample Cutting status Cutting Input Cut status Sew line SAM Manpower Efficiency W/HR PRO/DAY Sewing Status SEW COM Fin Status S.trm Acc Inspection V-Code Shp Swatch Blanket Shd band F.trmAccss Occurrence Remarks
229 2/15/2017 15-Jan Fit & PS 243 243 30.03 2 42 750 70% 11 7920 243 1 − 31 Ok Pass Ok Ok Ok Ok In Sewing Running
623 2/15/2017 15-Jan Fit & PS 654 654 30.08 2 42 750 70% 11 7920 456 1 − 31 Ok Pass Ok Ok Ok Ok In Sewing Running
209 2/15/2017 15-Jan Fit & PS 226 226 30.03 2 42 750 70% 11 7920 15 1 − 31 Ok Pass Ok Ok Ok Ok In
227 2/15/2017 15-Jan Fit & PS 248 248 30.03 2 42 750 70% 11 7920 15 1 − 31 Ok Pass Ok Ok Ok Ok In
151 2/15/2017 15-Jan Fit & PS 173 173 30.02 2 42 750 70% 11 7920 173 1 − 31 151 Ok Pass Ok Ok Ok Ok In Finishing Running
73 2/15/2017 15-Jan Fit & PS 91 91 30.01 2 42 750 70% 11 7920 91 1 − 31 73 Ok Pass Ok Ok Ok Ok In Finishing Running
4,000 2/15/2017 16-Jan Fit & PS 4122 4122 29.53 2 42 750 70% 11 7920 3489 2 − 1 Ok Pass Ok Ok Ok Ok In Sewing Running
2,312 2/15/2017 10-Jan Fit & PS 2325 2325 35.30 2 42 750 70% 11 7920 2325 1 − 26 2293 Ok Pass Ok Ok Ok Ok In Finishing Running
3,000 2/15/2017 16-Jan Fit & PS 3093 3093 29.39 2 42 750 70% 11 7920 3093 2 − 1 3050 Ok Pass Ok Ok Ok Ok In Finishing Running
2,300 2/15/2017 16-Jan Fit & PS 2416 2416 29.30 2 42 750 70% 11 7920 2416 2 − 1 2156 Ok Pass Ok Ok Ok Ok In Finishing Running
2,000 2/15/2017 16-Jan Fit & PS 2032 2032 29.26 2 42 750 70% 11 7920 2032 2 − 1 2001 Ok Pass Ok Ok Ok Ok In Finishing Running
3,000 2/15/2017 16-Jan Fit & PS 3089 3089 29.39 2 42 750 70% 11 7920 3089 2 − 1 2618 Ok Pass Ok Ok Ok Ok In Finishing Running
3,500 2/15/2017 16-Jan Fit & PS 3675 3675 29.46 2 42 750 70% 11 7920 3675 2 − 1 Ok Pass Ok Ok Ok Ok In Sewing Running

Garments Production Planning Related Interview Questions and Answers

  1. Who are the production planners in Apparel industry?

Production planners a person who does production planning in garments as per buyer order. His works started after getting confirmed order.

  1. How to do a production plan in a garments factory?

By distributing garments order to every line targeting on time delivery for production based on factory production capacity, using planning software, ERP or spreadsheet (Excel).

  1. How to execute garments production planning?

By making sure all necessary items for production in housed, completing all pre-production activities are primary steps execute production planning.

  1. Why need to do production planning in the apparel industry?

To give on time garments delivery to the customer (buyer), need to do accurate production planning in the apparel industry.

  1. How to implement production planning in a garments factory?

Ensuring effective planning and work accordingly.

  1. How to do a production planning report?

By excel production planning and production, the report can be done easily.

Written by

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

Linkedin: A.M. Amirul Islam

Duties and Job Responsibilities of Garments Buying House Technician

Duties and Job Responsibilities of Garments Buying House Technician

Buying House Technical Team: A buying house technician is a person, who is responsible to evaluate/review all types sample, make comments and approve or reject all types of the sample from buyer end. The person is also responsible for sample quality, works to improve sample and bulk quality, guide factory to improve quality. A buying house technical team consists of technicians where they know all types of Technical thing of a Garments factory. Here in this article, you will have detail idea of Duties and Job Responsibilities of Garments Buying House Technician. In a job description, all the duties and responsibilities are clearly disclosed.

Duties and Job Responsibilities of Garments Buying House Technician, Job Description of Garments Buying House Technician

Job Description of a Buying House Technician

  1. Evaluate all types of sample: Development, Proto, Fit, Size set, Jump size set, Seal, Buyer ref, etc. with a feasibility study of product & risk analysis. Timely identifying & resolving mass production impracticalities.
  2. Handle sample inspection and sample approval by reviewing construction, measurements, patterns, workmanship, garments outlook presentation, fitting (dummy and model), on fit sample and size set
  3. Recommend the process simplification & cost saving alternative options to the buyer
  4. Sealing of pre-production sample & handover style file for mass production.
  5. Provide buyer and factory QA advice on complex product items to factories before & during the manufacturing process.
  6. Participate in PP meeting, review pilot run, and monitor mass production for complex product and new vendor.
  7. Perform special assignment and case study for continuous improvement in quality & productivity.
  8. Assist maker technicians, QA for checking patterns, specifications & construction, and plan on quality according to company standards and requirements.
  9. Provide technical & quality control seminars & workshop for the vendor’s knowledge & skill improvement.
  10. Providing training, technical support for the vendor to implement E- pattern approval process.
  11. Perform an investigation to the customer claim case to find out a solution to minimize the repetition of the problem
  12. Provide required training/guidelines to garments maker to update/enhance their skills on technical, quality and operational capabilities.
  13. Provide technical support to Merchandising, Design Team, factories, overseas designers and vendors.
  14. Quality improving work of different sewing operation and implement in factory sewing line.
  15. Develop process quality and advice factory to follow.
  16. Responsible for all technical issue of garments.

Jobs in Buying House Technical Team

 Generally, we can find the following types of designation in buying house technical department.

  • Assistant Technician
  • Technician
  • Senior Technician
  • Assistant Technical Manager
  • Technical Manager

Duties and Job Responsibilities of Garments Buying House Technician pdf

Written by

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

Linkedin: A.M. Amirul Islam

Sewing Machine Operator Recruitment, Grading and Skill Matrix

Sewing Machine Operator Recruitment

Sewing operator recruitment is a tough job in the apparel industry. To recruit the best quality and efficient operator, sewing operators have to stitch one, two or three bundle garments with good seam quality by a certain time, recruiter checks his/ her production capacity and product quality and can be seen how many operations an operator can do, these few criteria set his grading. Then, Grade, wise operator salary is fixed by sewing operator recruiter, garments manufacturer have own operator grade wise salary standard. Here in this article, you will have details idea of Sewing Machine Operator Recruitment, Grading and Skill Matrix.

Sewing Machine Operator Recruitment, Grading and Skill Matrix in Garments

Related articles you may like:

  1. The job description of a sewing operator
  2. List of the sewing machine used in garments
  3. Different parts of a sewing machine

Sewing Operator Grading

Lots of factors have to consider when doing operator grading. First, we have to know what type of operation operator does, then the operator’s production efficiency and many others factor. Here you can see below information on how to grade sewing operator.

Sewing Operator Grading

SN. Operation Name M/C Type
“A” Grade Category
1 Pocket Attach SN
2 Placket Attach SN
3 Collar Attach SN
4 Collar Close SN
5 Zipper Join SN
6 Zipper Top Stitch SN
7 Placket Box Make SN
8 Neck Join OL
9 Sleeve Join OL
10 Side Seam OL
11 Bottom Join OL
12 Nk Piping  FL
13 Bottom Hem FL
14 Waist Band T /S Kansai
“B” Grade Category
1 Placket 1/16 Top Stitch SN
2 Bk Nk T/S (LBL T/S) SN
3 Back Rise Join OL
4 Front Rise Join OL
5 Shoulder Join OL
6 Front Nk T/S FL
7 Bk Nk Binding FL
8 Sleeve Hem FL
9 Arm Hole T/S FL
10 Shoulder Join OL
“C” Grade Category
1 Collar Tack SN
2 Side Vent Tack SN
3 Sleeve Inside tack SN
4 Sleeve Out Side Tack SN
5 BTN Hole BH
6 BTN Stitch BS
7 Bar Tack BT

Here,

  • SN – Single needle sewing machine
  • OL  -Overlock sewing machine
  • FL – Flat lock sewing machine
  • BH – Buttonhole sewing machine
  • BS – Button stitch sewing machine
  • BT – Bartack sewing machine

Explanation of Sewing Machine Operator Grading

  • For the each A grade operation giving 10 marks for 100% efficiency level up to a maximum of 8 operations, marks will be multiplying by the efficiency Percentage. (Example: 10X 0.7, if the efficiency level 70%.)
  • For each B grade operation giving 7 marks for 100% efficiency level up to a maximum of 8 operations, marks will be multiplying by the efficiency Percentage. (Example: 7X 0.7, if the efficiency level 70 %.)
  • For each C grade operation giving 5 marks for 100% efficiency level up to a maximum of 8 operations, marks will be multiplying by the efficiency Percentage. (Example: 5 X 0.7, if the efficiency level 70 %.)

General Grading of Sewing Machine Operator

  1. 10 marks will be given if the absenteeism less than 3%
  2. 5 Marks will be given for over one-year service in the factory
  3. 1 to 10 Marks will be given for types in satisfaction level of production management.
  4. To be an ‘A’ grade operators must have the ability to operate 3 different machine
  5. To be a ‘B’ grade operators, must have the ability to operate 3 different machine

Final Grading Based Marks of Sewing Machine Operator

  • 80> GRADE A
  • 70 > 80 GRADE B
  • 60 > 70 GRADE C

Sewing Operator Skills Matrix

Sewing operator skill matrix or summary is a database of operator production capacity of different operation, number of machine and operation with the name he can operate, these process efficiency, salary, date of join. The database makes in Excel (spreadsheet), keeping by IE department in the apparel industry. This database help factory to migrate operator to another operation, to find out best sewing operator easily, to do operator grading easily.

Sewing Machine Operator Recruitment, Grading and Skill Matrix

Sewing Operator Skill Summary List

  1. Number of operation can sew
  2. Number of sewing machine can operate
  3. Production capacity per operation
  4. Sewing efficiency
  5. Servicing period in factory
  6. Seam quality

Sewing Machine Operator Recruitment, Grading and Skill Matrix in Garments pdf

Written by

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

Linkedin: A.M. Amirul Islam

Garments Test Requirements of Buyer

Garments Test Requirements of Buyer

To ensure consumer product safety, wearability, garments quality, strength and others requirement of buyer, garments test is done as a buyer requirement. The test is conducted in full garments form not in fabrics form, safety is very much important for children garments. The garments test is done in buyer laboratory or in third-party laboratories or any nominated laboratories. The main objective of garments is to check consumer right and safety of a product, which is ensured by the test report. Garments test report is mandatory for every garments lot, without passing it shipment is not allowed. The cost of a test depends on the type of test you are asking. Garments testing criteria may little bit vary buyer to buyer but it is a mandatory requirement for all garments manufacturer. So as a garments maker you need to be careful about all garments test requirements of buyer otherwise you may lose your valuable customer. Another thing is, a good quality control system may give you the right product.

Garments Test Requirements of Buyer

List of Test Required for Garments

For your better understanding, I made a list of test normally required for garments which are asked by the garments buyers.

  1. Fiber content
  2. Care instruction
  3. Dimensional Stability To Home Laundering
  4. Distortion After Washing
  5. Appearance After 3 Washes
  6. Fabric Weight
  7. Tensile Strength
  8. Tear Strength
  9. Seam Strength / Slippage
  10. Color Fastness To Crocking
  11. Color Fastness To Ozone
  12. pH Value
  13. Dimensional Stability To Home Laundering
  14. Distortion After Washing
  15. Appearance After Washing
  16. Falling-Pendulum Type (Digital Elmendorf) Tester
  17. Colorfastness To Crocking
  18. Colorfastness To Ozone
  19. pH of The Water-Extract from Wet Processed Textiles
  20. Restricted substance list
  21. Sharp materials

Hopefully, this information will be helpful, If you need any detail information then please let me know. I will try to give your required information.

Garments test requirement of Buyer pdf

Written by

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

Linkedin: A.M. Amirul Islam

Fabrics Testing Requirements for Garments

Fabrics Testing Requirements for Garments

Fabrics Lab Testing: Fabrics need to pass through some testing for its quality, strength because by cut and sewing fabrics become garments, fabrics lab testing is very much important. Buyer has the requirement to pass the fabrics lab test report before allowing fabrics for garments manufacturing. Here you can find detail idea of fabrics testing requirements for garments, standard testing method and buyer required performance of every testing criterion, this would help you to know about all in-house fabrics testing and its standard testing method.

Fabrics Testing Requirements for Garments

Where does Fabrics Lab Test need?

  • Fabrics after dying, before delivery to garments
  • Fabrics before cutting, inspection stage of in garments manufacturing

List of Lab Testing Need to be Done of Fabrics

  1. Dimensional stability/Shrinkage to Laundering/washing
  2. Skew Test
  3. Distortion Test
  4. Dimensional stability to Dry Cleaning
  5. Appearance Rating
  6. Colorfastness to Laundering
  7. Colorfastness to Crocking
  8. Colorfastness to Perspiration
  9. Colorfastness to Water
  10. Colorfastness to Light
  11. Tensile strength
  12. Seam slippage
  13. Seam strength
  14. Tear strength
  15. Bursting strength
  16. Pilling resistance
  17. Fiber content
  18. Fabric weight (g/m2)
  19. Formaldehyde content
  20. Lead content (scrapable surfaces only; children only)
  21. Azoic Dyes

Fabrics Lab Testing Requirements and Standard Test Method

Fabrics Lab Testing Requirements and Standard Test Method

SL No Test Description Standard Test Method Performance Requirements
1 Dimensional stability/Shrinkage to Laundering/washing AATCC 135/150 Woven fabrics: +/- 3% max. Knitted fabrics: +/- 5% max.
2 Skew Test ASTM D3882  No skew
3 Distortion Test AATCC 179 Tolerance +/- 3%
4 Dimensional stability to Dry Cleaning AATCC 158 Woven fabrics: +/- 3% max. Knitted fabrics: +/- 3% max.
5 Appearance Rating Visual/AATCC 179, Method 2 Satisfactory, including no shape distortion, no cross staining and skewing 3% max for woven and 5% max for knits.
6 Colorfastness to Laundering AATCC 61 Color change: 4,  Color staining: 3, Self-staining: 4.5
7 Colorfastness to Crocking AATCC 8 Dry: 4, Wet: 3
8 Colorfastness to Perspiration AATCC 15 Color change: 4, Color staining: 3
9 Colorfastness to Water AATCC 107 Color change: 4, Color staining: 3
10 Colorfastness to Light AATCC 16 20-hour test: 3.5
11 Tensile strength ASTM D5034 Blouse: 25 lbs Shirt/dress/skirt/pyjamas/lining: 30 lbs Outerwear: 37 lbs Trousers/shorts/overall/pocketing: 50 lbs
12 Seam slippage ASTM D434 Blouse/shirt/dress/skirt:  15 lbs Pyjamas/lining: 18 lbs Outerwear/pocketing:  22 lbs Trousers/shorts/overall:  25 lbs
13 Seam strength ASTM D1683 Blouse/shirt/dress/skirt:  22 lbs Pyjamas/lining: 25 lbs Outerwear/pocketing:  30 lbs Trousers/shorts/overall:  37 lbs
14 Tear strength ASTM 1424 Blouse: 1.5 lbs Pyjamas/lining: 1.8 lbs Shirt/dress/skirt/outerwear: 2.0 lbs Trousers/shorts/overall/pocketing: 2.5 lbs
15 Bursting strength ASTM D3786 Fabric: 40 lbs /sq. inch, Seam: 35 lbs /sq. inch,
16 Pilling resistance ASTM 3512, – 30 minutes 3.5
17 Fiber content AATCC 20/20A +/- 3% tolerance for blends; No tolerance for single fiber
18 Fabric weight (g/m2) ASTM D3776 +/- 5% of specification
19 Formaldehyde content JIS L 1041 Garments with contact to skin < 75 ppm, Other garments < 300 ppm
20 Lead content (scrapable surfaces only; children only) 16 CFR 1500.3 < 600 ppm
21 Azoic Dyes Zero tolerance

Fabrics Testing Requirements for Garments pdf

Written by

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

Linkedin: A.M. Amirul Islam

Garments Quality SOP

Garments Quality SOP

Garments quality SOP is the standard operating procedure for quality control in Garments manufacturing. Setting Standard procedure for garments is very much important to get up to the mark of readymade garments. In a garments quality SOP, a clear description for every working system and requirement to get the best possible result is written. Following SOP, we can do any work in a standard way and know what to do to complete the whole operation. Garments buyer also gives SOP for handling their order. It is makers responsibility to follow while making their garments. Every garments factory has own SOP for every process they are involved with. Basically, a garments quality SOP is the written guidelines of standard procedure to do a particular work for making garments. Time to time standard process may change because garments involve with making different garments different times. Actually, a good standard operating procedure increases productivity by reducing the system loss or operating losses. In a garments factory a quality control department is responsible for ensuring the best quality of garments, so they always follow a standard process for monitoring and controlling process and products.

Garments Quality SOP, Garments Quality Standard Operating Procedure

List of SOP Needed for Garments Quality

Listed SOP hyperlinked with needed SOP, you can read by clicking.

  1. Fabrics inspection SOP
  2. Shade band procedure
  3. Fabrics process before cutting
  4. Trim and accessories inspection SOP
  5. Garments pattern making SOP
  6. Fabrics relaxation, spreading and cutting procedure SOP
  7. Sewing quality procedure
  8. Garments measurement SOP
  9. Needle controlling SOP
  10. Sharp edge controlling SOP
  11. Button pull test SOP
  12. Button pinch setting SOP
  13. Metal detection SOP
  14. Mold prevention SOP
  15. Finishing SOP
  16. Quality control manual or SOP

If you need any SOP for a specific process/ task related with quality or you want to develop a quality manual or any technical thing of garments manufacturing, please feel free to contact with me through sending mail to the following address.

Garments quality SOP pdf

Written by

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

Linkedin: A.M. Amirul Islam

Garments Quality Control Procedure

Garments Quality: Every garment buyer have own quality manual or procedure, a standard quality procedure should maintain in garments manufacturing industry to reach up to the mark in quality control. Every person related to apparel manufacturing need to know about garments quality procedures, especially for them who work in the quality department. Here I wrote all general garments quality control procedure of Garments manufacturing from cutting to finishing that’s how we do to maintain quality procedures.

Garments Quality Control Procedure

Garments Quality Control Procedure

  1. Checking fabrics, trims, and accessories as per buyer requirement.
  2. Make size set sample and review in PP meeting
  3. Pattern correction based on size set garments measurement
  4. Cut 300 pcs as a pilot run from all size range after PP meeting to ensure all size measurement is correct then proceed to cut for bulk.
  5. Keep pattern library of a printed pattern in the CAD room
  6. If fabrics shrinkage differs more than 2 %, a different pattern will be made
  7. Ensuring that fabric with accessories as per consumption okay to proceed bulk then start cutting
  8. Cutting will be started after buyer QC approval of bulk cutting
  9. Ensure all cut panels should be double check with pattern & maintain your record as per SOP
  10. All cut panels to be quality inspected before inputting to sewing section.
  11. Checking fabrics bonding strength with interlining after fusing, fusing attached temperature record with thermal paper.
  12. Keeping Go by sample for every running style to confirm garments styling is accurate as per sample.
  13. Ensure all marking instrument should be invisible especially pen & chalk mark pencil use light mark but it should be erased able daily basis, follow up oil leakage from the machine by put blotting paper or fabric under the pressure foot, also double check all the machine inside have any extra needle by the magnet.
  14. Ensure all machine tension with feed rock set up properly  by our actual fabric quality on daily basis & keep a record with mock-up
  15. Needle control and Needle change record maintain properly.
  16. 100% garments quality inspection in both sewing and finishing
  17. 100% garments to be measured in finishing
  18. Button pull test checking and record daily
  19. Garments pass through metal detector machine
  20. Keep packing accuracy as per buyer approval, check daily and take buyer approval for folding and packing

Garments Quality Control Procedure pdf

Written by

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

Linkedin: A.M. Amirul Islam

Overlock Sewing Machine Types, Specifications and Technical Adjustment

Overlock Sewing Machine

The overlock machine is different from the lockstitch sewing machine, cut the edge of fabrics and cover two parts of fabrics by stitching. Overlock machine has different types of specification, from 2/3 to 6 threads can be used. Here in this article, we will have detail discussion of Overlock Sewing Machine Types, Specifications and Technical Adjustment.

Overlock Sewing Machine

Overlock Sewing Machine Types, Specifications and Technical Adjustment

Overlock Stitch

Types of Overlock Sewing Machine

An overlock / over edge machine is a high-speed sewing machine. This is the quickest performing machine for giving overedge stitches. Overlock Machines Are available in following Specifications

  1. 2 Thread Overlock machine
  2. 3 Thread Overlock Machine
  3. 4 Thread Overlock Machine
  4. 5 Thread Overlock Machine
  5. 6 Thread Overlock Machine

Overlock Sewing Machine Types, Specifications and Technical Adjustment

The Relationship between Overlock Machine and Number of Thread Used

Serial No. Machine Name No. Of Threads use Total threads use
Needle Looper
1 2 Thread Overlock Machine 1 1 2
2 3 Thread Overlock Machine 1 2 3
3 4 Thread Overlock Machine 2 2 4
4 5 Thread Overlock Machine 2 3 5
5 6 Thread Overlock Machine 3 3 6

Features of Overlock Sewing Machine

  1. Maximum Machine speed 6500 SPM (vary operation wise)
  2. Stitch can be made using 2,3,4,5 or 6 threads, depending on the no. of needles and looper
  3. Stitch length 2 to 4 mm
  4. Stitching type- Overlock stitch
  5. Used feed is Deferential feed
  6. Oil lubrication system- Automatic
  7. Used in Woven, knit; all types of garments

Technical Adjustment of Overlock Machine

Technical adjustments which are to be taught while dealing with OVERLOCK machines are given below. Trainers should keep the following points in mind during the session of OVERLOCK machine

  • First, demonstrate the adjustment then ask trainee to practice on the machine.
  • Use the Instructional manual given by the machinery supplier during Session
  • Make sure, all the trainees are able to understand the Instructional manual.
  • The practice of sewing on a machine is also necessary.

Technical Adjustments Points of Overlock Machine

  1. Basic Machine Practice
  2. Technical Specification
  3. Installation of needle
  4. Needle bar Height adjustment
  5. Needle to lower looper timing
  6. Upper Looper Timing
  7. Chain looper timing (Safety Stitch)
  8. Upper Knife Adjustment
  9. Lower Knife adjustment
  10. Feed Dog Height adjustment
  11. Cam Timing
  12. Thread Adjustment

Overlock Sewing Machine Types, Specifications and Technical Adjustment pdf

Written by

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

Linkedin: A.M. Amirul Islam

Production Planning and Control in Garments

Production Planning and Control in Garments

Production Planning and Control (PPC): To ensure proper execution of production in the right time and on time delivery/shipment production planning is required. Production planning department’s responsibility is very sensitive to the apparel manufacturing point of view. Production planner distributes line wise production from buyer order list, set target to meet on time shipment date and execute everything for production. A wrong production plan can not ensure right time delivery, which is not a good sign of the apparel industry. Production planner distributes line wise production from buyer order list. Here in this article, we will have detail discussion of what are the things required Production Planning and Control in Garments and how you can execute it.

Production Planning and Control in Garments

Benefits of Production Planning in the Apparel Industry

  1. Keeping a sequence of production order
  2. Estimating production as per line wise capacity
  3. Achieving targeted production
  4. On time production and delivery to the customer

Things to Follow up by Planning Department

A production planner has to follow up below-mentioned work to implement production planning to progress production step by step.

  1. Fabrics, trims, and accessories in-house status
  2. Fabrics, trims and accessories inventory and inspection report
  3. QC file and approved sample receiving
  4. Size set /sampling requirement of the buyer
  5. PP meeting result; pass or fail
  6. Bulk cutting approval from buyer
  7. Cutting production
  8. Embroidery production
  9. Sewing production
  10. Washing production
  11. Finishing production
  12. Backlog of finishing
  13. Shipment

Factors of Garments Production Planning

These factors are key to develop a production plan for the apparel industry.

  1. Style name
  2. PO number
  3. Color
  4. Product category/type
  5. Style Description
  6. Order Quantity
  7. Price of every single unit Garments
  8. Ex-factory/shipment date
  9. Current Production status
  10. Planned final audit date
  11. Goods input date to sewing
  12. Planned Capacity / Day / Line
  13. Line Efficiency
  14. Number of Lines
  15. Name of a line for production
  16. Working Hour/Day
  17. Production Unit
  18. Weekend / Holidays during prod
  19. No of Working Day Required of every style
  20. Sewing Output Finish Date
  21. Wash Input Date
  22. Planned Capacity Per Day of washing
  23. Production Unit of washing
  24. No of Working Day Required to complete washing
  25. Wash Completing date
  26. Dry Process; apply or not apply
  27. Goods Finishing Start Date
  28. Planned Capacity Per Day of finishing
  29. Weekend/Holiday during production in finishing
  30. No of Working Day Required to complete finishing
  31. Goods Will Ready for final Audit
  32. Factory Wise Planned Production Capacity Sewing
  33. No Of line /Production Unit in the facility
  34. Factory Wise Planned Production Capacity Wash
  35. The quantity of Dry Process / Normal Wash

Implementation of Garments Production Planning

Implementation of production is not a very easy task for the garments industry as its change with time. Production plan implementation starts with cutting and finish with the packing of garments, long working between start and finish. A factory may get fabrics delay or trims or may fabrics can be failed in inspection for shade or visual defects, these problems hamper time and production planner has to change plan, may input next lot for production because you cannot keep line stop from production. So anything delay, next lot can be inputted for production keeping shipment date in mind. Plan updates every day depending on the current situation.

Finally, Production planning is a continuous process as the production of a different lot is going on but you also required to maintain a good control system. By monitoring, you can identify whether your planning is perfectly working or not, if not then a control is required to take corrective action.

Production planning and control in Garments pdf

Written by

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

Linkedin: A.M. Amirul Islam

Shade Band Submission and Approval Procedure in Garments Factory

Shade Band Submission and Approval Procedure in Garments Factory

Before discussing Shade Band Submission and Approval Procedure in Garments Factory first let have some idea of what is shade band and why we need shade band so that you can understand the importance of shade band submission.

What is Shade Band?

Shade band is a color standard range for color evaluation process of finished garments to get garments within buyer standard color range.

Why need Shade Band?

To ensure consistent shade, swatches from every roll & lot must be collected and placed on the “Color Continuity Card” for color assessment. Garments maker need to complete the bulk fabric shade band submission. No bulk production can begin until the merchandiser has signed off the Color Continuity.

Shade Band Submission and Approval Procedure in Garments Factory

Shade Band Submission Procedure in Buying House

  1. Submit the Color Continuity Cards to QC/Wash or fabrics QC or merchandisers.
  2. Buying house is responsible for the sign off of Color Continuity Cards.
  3. Collect swatches: Samples must be taken from every bulk lot of main and trim fabric. During the fabric inspection, the factory should cut the color samples from each roll or each dye lot displaying the range of color variation. Swatches must be taken from the front and end of the roll. Write the corresponding lot/roll number for identification.
  4. Garment wash: The swatches may be sent to a washing factory to check the color changes under one wash batch, which is subjected to the washing/ after treatment.
  5. Sorting the swatches into color batches – Put the swatches under the lightbox using TL84 and D60 to assess for any color variation. The swatches are compared to the fabric approval card and trim approval card. Group the swatches to different shade lots such as A, B, C, D, E… Mark the lot number on each swatch.
  6. Prepare the Color Continuity card: A 15 cm by 15 cm cutting from the swatches of each lot should be mounted on the Color Continuity Cards and fill in the appropriate column with an appropriate “lot number”. The total yardage of each dye lot is then recorded.
  7. Approval of Color Continuity card: The Color Continuity Card is prepared in a 3 duplicate set. Buying house responsible QC or merchandiser review these shade bands. Once the shade band has been agreed, a respective person should sign off one of the duplicate copies and return to factory for a record. Such copy should be kept in the factory laboratory for reference and the warehouse computer program is updated for roll shade identification. One of the duplicates may be sent to customers for approval or for reference. One of the duplicates will be kept in QC file. QC will use this as a standard for inspections.
  8. Agree with shade band: To control the color variation, an acceptable shade band should be agreed between buying house, buyer and garments maker prior to the cutting process. The color of bulk production must fall within the agreed shade band. In case the shade band is out of standard, advise the factories to contact their dying mills for improvement. Should there be extreme cases of shade variations, this will then be raised to QC manager and Merchandise Manager for decision making or eventually to customers.
  9. Generally, 4 sets of Shade Band approve by buying house, 1 keeping in buying house, 1 for wash factory and two for garments maker
  10. Shade/color evaluation of garments with buying house approved shade band should be under lightbox, at least 1000 lx light should be of buyer required light.

If you have any question of Shade Band Submission and Approval Procedure in Garments Factory please let me know. I will try to give you more details.

Shade Band Submission and approval procedure in Garments factory pdf

Written by

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

Linkedin: A.M. Amirul Islam