Inventory Management in Apparel Industry

Inventory Management in Apparel Industry

Management of inventory is not an easy task; you need to be careful when you work with inventory management. Textile and garments industry is huge in terms of volume of production as the demand for clothes is increasing day by day. In an apparel industry, you may have to keep inventory in different forms. It can be of raw materials or finished goods. Because of the extra burden of improper inventory planning every year apparel industry incurring a huge cost which ultimately decreasing the profitability of that company. Sometimes they lost their price competitiveness because of poor inventory management. I was talking with a manager of renowned garments, he told me that because of improper inventory management system we had too much wastage or damaged inventory. Which ultimately decreases our profit margin. Now we are concern about it and trying to develop a good inventory management system. Here in this article, I will try to give you a general guideline of how you can ensure a good inventory management in apparel industry.

Inventory Management in Apparel Industry

List of Inventories in Textile and Garments Industry

  1. Raw Materials (Yarn, Dyes Chemicals, Packing Materials, Trims and Accessories etc.)
  2. Semi Processed Materials (Gray Fabric)
  3. Finished Goods (Garments Products)

 General Guidelines of Inventory Management in Apparel Industry

  1. First of all, you can calculate economic order quantity (EOQ), but here the problem is to determine the annual demand. It is too tough but if you were doing business for many years and you have all your previous year demand records then you can decide what will be the future demand. All you have to do is to increase the value of demand with the annual growth of your business. Here economic order quantity indicates a specific order quantity where the total cost of ordering and storing is minimum.

EOQ in Apparel Industry

Example: Suppose last few years your annual demand of a particular material was 200 MT. And with the increase in your production, this demand is increasing by 20%. So for next year, you can assume that your annual demand will be 200 + (200 x 20%) = 240 MT.

  1. Calculate reorder point: Place order when inventory stock reaches to a particular level.
  2. Calculate lead time and make a decision: Calculate how much time is required to place an order and receiving those goods to the factory.
  3. The requirement of safety stock of investors: Identify is there any requirement of keeping safety stock or not. If safety stock is required then how much should we keep is to be determined.
  4. Whether there are any materials you can deliver real-time basis or not. If it is possible for some raw materials then please make a list of it.
  5. A proper record should be kept both manual (bin card, registry book), and computer-based database.
  6. Every issues and receive must be recorded properly
  7. Ensure a good warehouse condition for inventories so that no bug can spoil your valuable materials.
  8. Proper inventory valuation method needs to be used and keep records of all valuation data
  9. Inventories of different level should be kept in separate room or areas so it is not mixed-up
  10. One most important thing is, overproduction will create an extra burden of selling and unsold items will occupy our store. Management of this inventory will be extra work. So proper planning is required to ensure the production of the right quantity, not over not under.

If you want to learn details calculations of different inventory management tools then please let me know. I will try to provide you detail clarification with examples.

Inventory Management in Apparel Industry.pdf

Written by

Md. Nahian Mahmud Shaikat

Operation breakdown and SMV Polo Shirt

Operation breakdown and SMV Polo Shirt

Polo shirt is a special type of shirt which has a collar and a placket with two or three buttons, different from a T-shirt, also have a pocket. Polo is also made of knit fabric like T-shirt but different types of design. Total SMV of Polo Shirt is 10.39. This operation breakdown includes a list of operation, machine list, SMV of every single operation, the production target of polo shirt manufacturing in the sewing section. Hopefully, after reading this article you will have an idea of detail Operation breakdown and SMV Polo Shirt.

Operation breakdown and SMV Polo Shirt

Operation Breakdown and SMV Polo Shirt
NO OPERATION M/C S.M.V TGT MAN REQ MAN ALCT Plan Work Station
1 CARE LABEL CUT, ARRANGE & ATT SNL 0.35 171 0.98 1 1
2 PLACKET & BODY STICKER MATCH MNL 0.12 500 0.33 0.5 1
3 PLACKET ROLLING & MARK SNL 0.35 171 0.98 1 1
4 PLACKET ATTACH SNL 0.42 143 1.17 1 1
5 PLACKET SCISSORING & NOSE TACK SNL 0.32 188 0.89 1 1
6 BK MOON IRON IRN 0.32 188 0.89 1 1
7 MAIN & SIZE LABEL ATTACH SNL 0.4 150 1.12 1 1
8 MOON ATTACH SNL 0.35 171 0.98 1 1
9 FRT & BK STICKER MATCH MNL 0.15 400 0.42 0.5 1
10 SHOULDER JOIN & cut OL 0.3 200 0.84 1 1
11 COLLAR  SERVICING OL 0.2 300 0.56 1 1
12 COLLAR MARK MNL 0.15 400 0.42
13 COLLAR ATT W/BK TAPE SNL 0.37 162 1.03 1 1
14 BK TAPE TS SNL 0.33 182 0.92 1 1
15 LOWER PLACKET CLOSE SNL 0.22 273 0.61 0.5 1
16 UPPER PLACKET TS SNL 0.2 300 0.56 0.5
17 PLACKET BOX SNL 0.4 150 1.12 1 1
18 CUFF JOIN OL 0.4 150 1.12 1 1
19 CUFF TS FL 0.27 222 0.75 0.5 1
20 Slv Pair Match MNL 0.15 400 0.42 1 1
21 Slv& Body Sticker Match MNL 0.25 240 0.7
22 SLEEVE JOIN OL 0.42 143 1.17 1 1
23 ARMHOLE TS FL 0.32 188 0.89 1 1
24 BTM HEM FL 0.32 188 0.89 1 1
25 SIDE SPLIT TK SNL 0.27 222 0.75 1 1
26 SIDE SPLIT ROLLING BY TS SNL 0.5 120 1.4 1.5 2
27 SIDE SEAM OL 0.57 105 1.59 1.5 2
28 SLEEVE OPEN & CLOSE TK & RAW EDGE TK SNL 0.45 133 1.26 1 1
29 SEW BTN HOLE BH 0.3 200 0.84 1 1
30 BTN ATTACH POSITION MARK MNL 0.15 400 0.42 0.5 1
31 BTN ATTACH BA 0.27 222 0.75 1 2
32 BTN PUSH MNL 0.2 300 0.56 0.5 2
33 STICKER REMOVE (4) MNL 0.15 400 0.42 0.5 1
34 FINAL THREAD CUT MNL 0.45 133 1.26 1 1
 Total   10.39   29 29 35

Summary of Operation Breakdown and SMV Polo Shirt

Summary of Operation breakdown and SMV Polo Shirt
Inline S.M.V
SEWING 8.3
MANUAL 1.77
IRON 0.32
TOTAL 10.39
Man level 29
Pitch time 0.358
100% Tgt/h 167
75% Tgt/h 126
70% Tgt/h 117
Machine type Requisition
OL 6
SNL 14
VT 0
BA 1
BH 1
FL 3
BT 0
Total 24
Manpower Requisition
Operator 24
Iron Man  0
MANUAL 5
Total 29

Operation breakdown and SMV Polo Shirt excel

Summary of Operation breakdown and SMV Polo Shirt

Written by

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

Linkedin: A.M. Amirul Islam

Operation Breakdown and SMV of T-shirt of Knit Garments

Operation Breakdown and SMV of T-shirt of Knit Garments

T-shirt named for its T shape, collarless and short sleeves. Generally, a T-shirt made by light cotton fabrics, very comfortable to wear, casual wearing dress. A T-shirt is more comfortable than Polo shirt, male and female both can wear it. This article is all about T-shirt manufacturing, operation breakdown of T-shirt. Total SMV of T-shirt is 8.41. From this article, you will know, list of operation, machine list, SMV of every single operation, the production target of T-shirt manufacturing in the sewing section. So, let’s have a look at Operation Breakdown and SMV of T-shirt of Knit Garments.

Operation Breakdown and SMV of T-shirt of Knit Garments

Operation Breakdown and SMV of T-shirt of Knit Garments
NO OPERATION M/C S.M.V TGT MAN REQ MAN ALCT Plan Work Station 
1 CARE LABEL ATTACH SNL 0.12 500 0.36 0.5 1
2 PLACKET ATTACH POSITION MARK MNL 0.25 240 0.74 0.5 1
3 PLACKET ROLLING & MARK SNL 0.32 188 0.95 1 1
4 PLACKET ATTACH SNL 0.4 150 1.19 1 1
5 PLACKET CUT & NOSE TK SNL 0.27 222 0.8 1 1
6 FRONT & BACK PART MATCH MNL 0.15 400 0.45 0.5 1
7 SHOULDER JOINT 4OL 0.3 200 0.89 1 1
8 NOSE NECK RIB MEASURE & CUT MNL 0.2 300 0.59 0.5 1
9 NOSE NECK RIB TK WITH BODY SNL 0.32 188 0.95 1 1
10 NOSE NECK RIB JOIN 4OL 0.32 188 0.95 1 1
11 NECK TS FL 0.25 240 0.74 0.5 1
13 PLACKET CLOSE & 1/16 UPPER SNL 0.32 188 0.95 1 1
12 PLACKET CLOSE & 1/16 LOWER SNL 0.32 188 0.95 1 1
14 PLACKET BOX SNL 0.4 150 1.19 1 1
15 NECK PIPING FB 0.23 261 0.68 1 1
16 MAIN LBL ATTACH WITH CORNER FOLD SNL 0.32 188 0.95 1 1
17 SLV HEM FL 0.33 182 0.98 1 1
18 SLEEVE AND BODY MATCH MNL 0.15 400 0.45 1 1
19 SLEEVE JOINT 4OL 0.45 133 1.34 1 1
20 ARMHOLE T/S FL 0.32 188 0.95 1 1
21 SIDE SEAM 4OL 0.7 86 2.08 2 2
22 SLEEVE CLOSE & OPEN TACK SNL 0.37 162 1.1 1 1
22 BODY HEM FL 0.33 182 0.98 1 1
22 BUTTONHOLE BH 0.3 200 0.89 1 1
22 BUTTON ATTACH MARK BS 0.27 222 0.8 1 1
22 BUTTON PUSH MNL 0.2 300 0.59
22 FINAL THREAD CUT & STICKER REMOVE MNL 0.5 120 1.49 1 1
Total 8.41 25 25 27

Here,

  • 5OL – 5 thread overlock
  • 4OL – 4 thread overlock
  • SNL – Single needle lock stitch
  • FB – Flat belt
  • KS – Kansai machine
  • BS – Button stitch m/c
  • FL – Flat lock m/c
  • BH – Button hole m/c
  • M/C – Machine
  • TGT – Target
  • MAN REQ – Man Requirement
  • MAN ALCT – Man Allocation

Summary of T-shirt Operation Bulletin

Summary of T-shirt Operation Bulletin
Inline S.M.V
SEWING 6.96
MANUAL 1.45
IRON 0
TOTAL 8.41
Man level 25
Tact time 0.336
100% Target/hour 178
75% Target/hour 134
65% Target/hour 116
Machine Type Requisition
5OL 0
4OL 5
SNL 10
FB 1
KS 0
BS 1
FL 4
BH 1
Total 21
Manpower Requisition
Operator 21
Iron Man  0
MANUAL 3
Total 24

Summary of T-shirt Operation Bulletin

Operation Breakdown and SMV of T-shirt of Knit Garments excel

Written by

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

Linkedin: A.M. Amirul Islam

Operation Breakdown and SMV of Cargo Pant

Operation Breakdown and SMV of Cargo Pant

Cargo Pant: Cargo Pant is a pant includes cargo pocket, generally loose-fitting, comfortable casual wear. Cargo Pant can be the long and short type of. Here SMV, total SMV found 36.28 which can be varied factory to factory. This data will give you a clear idea about the list of operation of cargo pant and their SMV. For a cargo pant, you may find more process are involved than 5 pocket pant. Hopefully, Operation Breakdown and SMV of Cargo Pant which be helpful for you.

Operation Breakdown and SMV of Cargo Pant
NO OPERATION M/C TYPE Count SMV TARGET 100% Efficiency TARGET 80% Efficiency
FRONT PART
1 FLY FUSING IRN 1 0.25 240 192
2 S/FLY +D/FLY + FNT RISE +SEAM+ FACING SERGING 5 OL 1 0.45 133 107
3 BODY SERIAL + THREAD CUT Helper 1 0.2 300 240
4 SEAM MARK Helper 1 0.3 200 160
5 FACING JOIN WITH PKTING + D/FLY MAKE SNL 1 0.35 171 137
6 SEAM JOIN  WITH PKTING SNL 1 0.35 171 137
7 FNT PKTING  JOIN WITH BODY SNL 1 0.4 150 120
8 FNT PKT MOUTH ROLLING DNL 2 0.5 120 192
9 FNT PKT HORI+VER TACK SNL 1 0.4 150 120
10 FNT PKT BAG O/L 3 OL 1 0.35 171 137
11 PKT BAG TOP 1/4 SNL 1 0.38 158 126
12 S/FLY JOIN + TOP STC SNL 1 0.35 171 137
13 ZIPPER JOIN DNL 1 0.3 200 160
14 J TOP STC WITH MARK DNL 1 0.35 171 137
15 D/FLY JOIN + BODY CLOSE SNL 1 0.4 150 120
16 FNT RISE INSIDE TACK SNL 1 0.5 120 96
17 FNT RISE TOP STC SNL 1 0.55 109 87
18 CARE LABEL MAKE + JOIN WITH WAIST SNL 1 0.25 240 192
19 FNT PART CHECK QC
20 MAKE SECTION
21 FLAP +W/BELT FUSING IRN 1 0.2 300 240
22 REINFORCEMENT CREASING (4 PICS) IRN 4 0.4 150 480
23 FLAP TOP STC SNL 1 0.4 150 120
24 THAI PKT DART MAKE SNL 2 0.35 171 274
25 THAI PKT DART TOP STC SNL 1 0.28 214 171
26 THAI +BK PKT FLAP MAKE SNL 2 0.6 100 160
27 THAI +PKT FLAP TOP 1/4 SNL 2 0.5 120 192
28 THAI PKT O/L 3 OL 1 0.3 200 160
29 THAI PKT+THAI COIN PKT ROLLING SNL 1 0.4 150 120
30 THAI COIN PKT LOOP JOIN+DECO STC SNL 1 0.4 150 120
31 THAI COIN PKT VELCO JOIN VELCRO 1 0.4 150 120
32 THAI  COIN PKT JOIN SNL 1 0.45 133 107
33 BACK PART
34 BK RISE JOIN SNL 2 0.65 92 148
35 BK RISE TOP STC DNL 1 0.62 97 77
36 BK PKT SERGING 5 OL 1 0.55 109 87
37 BK PKT ROLLING SNL 1 0.35 171 137
38 BK PKT+FLAP POSITION MARK Helper 2 0.65 92 148
39 BK PKT JOIN WITH REINFORCEMENT SNL 2 0.4 150 240
40 BK PKT 1/4 SNL 2 0.3 200 320
41 BK PKT PLAP JOIN DNL 1 0.5 120 96
42 BK PART LBL JOIN SNL 1 0.3 200 160
43 BK PART CHECK QC
44 ASSEMBLY
45 FNT+ Bk PART +  MATCHING Helper 1 0.3 200 160
46 SIDESEAM JOIN 5 OL 1 0.48 125 100
47 SIDE SEAM TOP STC FOA 1 0.4 150 120
48 MARK THAI PKT, BTM HEM Helper 2 0.45 133 213
49 THAI PKT JOIN SNL 2 0.7 86 137
50 THAI PKT 1/4 SNL 2 0.6 100 160
51 FLAP MATCH Helper 1 0.2 300 240
52 FLAP JOIN SNL 1 0.4 150 120
53 FLAP TOP STC SNL 1 0.48 125 100
54 LOOP MAKE FL 1 0.35 171 137
55 MARK LOOP JOIN + CUT Helper 1 0.4 150 120
56 BON PKT POSITION MARK SNL 2 0.65 92 148
57 BON ROLLING SNL 1 0.3 200 160
58 BON MACHING +BON LENGHT MARK Helper 1 0.2 300 240
59  BON CREASING IRN 1 0.4 150 120
60 BON JOIN DNL 1 0.7 86 69
61 BON CUT + TURN OVER Helper 1 0.35 171 137
62 BON TOP STC DOWNSIDE SNL 1 0.65 92 74
63 BON PKTING HARMONIUM  FACING  SERGING 5 OL 1 0.52 115 92
64 BON PKTING SERGING 5 OL 1 0.45 133 107
65 BON PKT FACING JOIN WITH PKTING SNL 2 0.7 86 137
66 BON TOP STC UPPER SIDE SNL 1 0.6 100 80
67 BK BON PKT INSIDE TACK SNL 1 0.55 109 87
68 W/ BELT MARK+ ALLOWANCE CUT Helper 1 0.35 171 137
69 W/BELT CREASING IRN 1 0.35 171 137
70 W/BELT POSITION MARK Helper 1 0.25 240 192
71 W/BELT MATCHING SNL 1 0.3 200 160
72 W/BELT JOIN SNL 3 0.85 71 169
73 W/BELT ELASTIC CUT + MARK Helper 1 0.4 150 120
74 W/BELT ELASTIC TACK SNL 2 0.55 109 175
75 W/BELT TOP STC(ELASTIC PART) K-S 1 0.55 109 87
76 W/BELT TOP STC K-S 2 0.75 80 128
77 MOUTH CUT Helper 2 0.35 171 274
78 MOUTH  REMOVE Helper 2 0.3 200 320
79 MOUTH CLOSE SNL 2 0.84 71 114
80 LOOP DEEP TACK SNL 1 0.6 100 80
81 INSEAM JOIN 5 OL 1 0.35 171 137
82 INSEAM TOP STC FOA 1 0.38 158 126
83 BTM HEM ROLLING SNL 2 0.75 80 128
84 VELCROW POSITION MARK Helper 2 0.65 92 148
85 VELCROW JOIN VELCROW 2 0.75 80 128
86 FINAL THREAD CUT Helper 2 0.5 120 192
87 FINAL TABELTE QC
88 TOTAL 107 36.28 2 142

Here,

  • IRN- Iron Machine
  • SNL- Single needle lock stitch
  • DNL- Double needle lock stitch
  • 3 OL- 3 thread overlock
  • 5 OL- 5 thread overlock
  • VERT- Vertical Machine
  • DNL- Double needle lockstitch machine
  • K-S – Kansai machine
  • FOA- Feed of the arm

Operation Breakdown and SMV of Cargo Pant

Operation Breakdown and SMV of Cargo Pant excel

Written by

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

Linkedin: A.M. Amirul Islam

Operation Breakdown and SMV 5 Pockets Long Pant

Operation Breakdown and SMV 5 Pockets Long Pant

5 Pocket pant can be long or short, most commonly manufactured in the apparel industry, 3 pocket in the front side and 2 in the back. Generally, 5 Pocket pant is Slim Fit Skinny Leg types. 5 pocket pants can be made by jeans or non-denim Twill Pant. Nowadays 5 pockets jeans pant is very commonly used garments and it is very popular. This article will help you to know about a list of operation and SMV of 5 pocket long pant. Hopefully, you will understand after reading Operation Breakdown and SMV 5 Pockets Long Pant.

Operation Breakdown and SMV 5 Pockets Long Pant
NO. OPERATION M/C TYPE No. of Machine  SMV TGT in 100% Efficiency
FRONT PART
1 FNT FLY FUSING ATT IRN 1 0.2 300
2 FNT PART KNEE MARK Helper 1 0.25 240
3 S/FLY +D/FLY MAKE+FNT RISE O/L 3 OL 1 0.3 200
4 D/FLY OL +SEAM OL 3 OL 1 0.3 200
5 FNT PKT SEAM  MARK Helper 1 0.3 200
6 COIN PKT ATT TO SEAM SNL 1 0.3 200
7 FNT PKT SEAM + FACING  ATTACH TO PKTING SNL 1 0.3 200
8 FNT PKTING ATTACH TO BODY SNL 1 0.25 240
9 FNT S/FLY ATT +  TOP STC SNL 1 0.3 200
10 FNT S/FLY ZIPPER ATT DNL 1 0.3 200
11  J STC MARK Helper 1 0.2 300
12  J TOP STC DNL 1 0.25 240
13 FNT D/FLY JOIN SNL 1 0.25 240
14 FNT D/FLY BODY CLOSE SNL 1 0.25 240
15 FNT RISE INSIDE TACK+ROLLING SNL 1 0.35 171
16 FNT RISE TOP STC SNL 1 0.3 200
17 FNT RISE 2ND STC WITH DIMOND SNL 1 0.25 240
18 FNT PKT  MOUTH ROLLING WITH PIPING DNL 2 0.55 109
19 FNT PKT HORI+VERTI- TACK SNL 1 0.4 150
20 FNT PKT BAG OL +TURN 3 OL 1 0.3 200
21 FNT PKT BAG 1/4 TOP STC SNL 2 0.4 150
22 LABLE MAKE SNL 1 0.25 240
23 FNT PART LABLE ATT SNL 1 0.3 200
24 FNT PART WAIST MARK Helper 1 0.25 240
25 FNT PART CHECK QC
26 BK PART 
27 BK PART KNEE MARK Helper 1 0.25 240
28 BK YOKE JOIN 3 OL 1 0.3 200
29 BK YOKE JOIN TOP STC FOA 1 0.3 200
30 BK RISE  JOIN 3 OL 1 0.3 200
31 BK RISE TOP STC FOA 1 0.28 214
32 BK PKT + LOOP + YOKE + CORD MARK Helper 2 0.4 150
33 BK PKT MOUTH ROLLING+COIN PKT ROLLING CHIN 1 0.45 133
34 BK PKT OL 3 OL 1 0.3 200
35 BK PKT IRN IRN 2 0.6 100
36 BK PKT ATT SNL 2 0.6 100
37 BK PKT TOP STC SNL 2 0.5 120
38 BK PART CHECK QC
39 ASSEMBLY
40 FR.+BK PART MACHINE Helper 1 0.3 200
41 INSEAM JOIN TOP STC (FOLDER) FOA 2 0.55 109
42 SIDE SEAM O/L 5 OL 2 0.6 100
43 SIDE SEAM SAFT STC SNL 2 0.6 100
44 SIDE SEAM CORD STC SNL 2 0.4 150
45 SIDE SEAM LABLE ATT SNL 1 0.3 200
46 W/BELT SHARING 5 OL 1 0.3 200
47 W/BELT FUSING ATT IRN 1 0.3 200
48 W/BELT MARK Helper 1 0.3 200
49 W/BELT MATCHING Helper 1 0.3 200
50 W/BELT JOIN  TOP STC  ( FOLDER) K-S 2 0.65 92
51 W/B CHECK+IN SIDE CHECK Q.I
52 W/BELT MOUTH CUT+TREAD REMOVE Helper 2 0.45 133
53 W/BELT MOUTH CLOSE SNL 3 0.8 75
54 WAIST LOOP MAKE(FOLDER)+LOOP CUT+MATCHING SNL 1 0.3 200
55 WAIST  LOOP & BELT  IRN IRN 1 0.26 231
56 WAIST LOOP ATT  (5PCS) SNL 2 0.5 120
57 WAIST LOOP CLOSE SNL 1 0.35 171
58 W/BELT LABLE ATT SNL 1 0.3 200
59 BTM HEM ROLLING SNL 2 0.6 100
60 TRIM CUT Helper 2 0.3 200
61 FNT PKT WASH TACK +MOUTH TACK SNL 1 0.3 200
62 BERTECK & BUTTON SECTION
63 LOOP BERTECK (10 pics) BERTEK 2
64 BK PKT BERTECK+CORD STC BERTEK 1
65 FNT PKT BERTECK+FLY BERTEK 1
66 EYELET HOLE HOLE 1
67 FLAP MARK & BODY CARING Helper 1
68 REVEAT ATTACH(10 POINT) SNAP BUTTON 2
69 WAIST BUTTON SNAP BUTTON 1
70 WAIST MARK Helper 1

Here,

  • IRN- Iron Machine
  • SNL- Single needle lock stitch
  • 3 OL- 3 thread overlock
  • VERT- Vertical Machine
  • DNL- Double needle lockstitch machine
  • K-S – Kansai machine
  • FOA- Feed of the arm

Operation Breakdown and SMV 5 Pockets Long Pant

Operation Breakdown and SMV 5 Pockets Long Pant excel

Written by

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

Linkedin: A.M. Amirul Islam

Operation Breakdown and SMV of Men’s Long Sleeve Shirt

Operation Breakdown and SMV of Men’s Long Sleeve Shirt

Operation Breakdown for Garments ManufacturingOperation breakdown is a list of processor operation in sequence wise with SMV or SAM and machine Helper list. Style-wise operation breakdown is done by an industrial engineer in an excel chart. Operation breakdown report help to set the line layout of every style. For your better understanding, I made an Operation Breakdown and SMV of Men’s Long Sleeve Shirt in an excel sheet.

Operation Breakdown Report Includes

  1. List of operation
  2. Operation wise needed sewing machine list
  3. Operation wise number of  sewing machine
  4. SMV or SAM of every operation
  5. Production target of every operation

Operation Breakdown and SMV of Men’s Long Sleeve Shirt

OPERATION M/C TYPE Number of Machine Needed SMV Target Production in 100% Efficiency(Pcs) Target Production in 80% Efficiency(Pcs)
MAKE SECTION-SMALL PARTS
COLLER FUSING IRN 2 0.25 240 192
COLLAR MAKE MARK + MATCH HELPER 1 0.25 240 192
COLLAR MAKE WITH HELPER THREAD SNL 2 0.45 133 213
COLLAR ALLOWANCE CUT HELPER 1 0.25 240 192
COLLAR TURN + THREAD REMOVE HELPER 1 0.25 240 192
COLLAR TOP 1/4 STC SNL 2 0.32 188 300
COLLAR + BAND MATCH HELPER 1 0.3 200 160
BAND JOIN SNL 2 0.55 109 175
COLLAR ALLOWANCE NOSE  CUT + SERGING 3 OL 1 0.35 171 137
BAND TOP (MIDDLE)  STC SNL 1 0.3 200 160
COLLAR  MARK SHOULDER PSN HELPER 1 0.3 200 160
FLAP IRN IRN 2 0.45 133 213
FLAP MAKE SNL 2 0.6 100 160
FLAP TOP STC SNL 2 0.55 109 175
FLAP PEN POINT MARK+ROLLING SNL 3 0.4 150 360
MARK FOR CUFF MAKE HELPER 1 0.35 171 137
CUFF MAKE SNL 1 0.5 120 96
CUFF MAKE VERT 1 0.4 150 120
CUFF TOP STC SNL 2 0.6 100 160
BACK PART
BACK PART DART MAKE SNL 1 0.25 240 192
MAIN + FIT LBL ATT WT BACK YK SNL 2 0.3 200 320
BACK YK ATT 3 PARTS SNL 2 0.28 214 343
BACK YK TOP STC SNL 1 0.4 150 120
CARE LBL ATT SNL 1 0.3 200 160
BACK NECK TRIMMING HELPER 1 0.5 120 96
BACK PART CHECK QC
FRONT PART
BOX PLATE MAKE K-S 2 0.55 109 175
THREAD CUT HELPER 1 0.2 300 240
BTN PLATE MAKE SNL 1 0.5 120 96
FRONT NECK TRIMMING HELPER 1 0.3 200 160
ASSEMBLY
BACK + FRONT PART MATCH HELPER 1 0.2 300 240
SHOULDER JOIN SNL 2 0.3 200 320
SHOULDER T/S DNL 1 0.25 240 192
POCKET + FLAP MARK HELPER 2 0.45 133 213
POCKET ROLLING SNL 1 0.2 300 240
POCKET IRN IRN 2 0.2 300 480
PLACKET IRN IRN 2 0.5 120 192
POCKET MATCH HELPER 1 0.25 240 192
POCKET JOIN SNL 2 0.6 100 160
POCKET 1/4 SNL 2 0.55 109 175
FLAP MATCH HELPER 1 0.2 300 240
FLAP JOIN DNL 2 0.5 120 192
NECK SHARING SAFETY STC SNL 1 0.25 240 192
COLLAR + BODY ASSEMBLY HELPER 1 0.25 240 192
COLLAR JOIN SNL 2 0.45 133 213
COLLAR CLOSE  TOP STC SNL 3 0.65 92 222
SLEEVE PLACKET OPEN MARK + CUT HELPER 1 0.3 200 160
GANBLE JOIN( FOLDER) SNL 1 0.35 171 137
GANBLE TACK + EXCESS CUT SNL 1 0.3 200 160
PLACKET JOIN + EDGE TOP STC SNL 2 0.4 150 240
CUFF JNS PSN MARK HELPER 1 0.25 240 192
SLEEVE MATCHING HELPER 1 0.2 300 240
SLEEVE JOIN 3 OL 2 0.5 120 192
SLEEVE INSIDE ALLOWANCE CUT HELPER 1 0.25 240 192
ARMHOLE TOP STC ( FOLDER) DNL 2 0.6 100 160
THEAD CUT + ALLOWANCE CUT 3OL 1 0.35 171 137
SIDE SEAM TOP STC FOA 2 0.45 133 213
CUFF  JOIN PSN MARK HELPER 1 0.35 171 137
CUFF JOIN SNL 3 0.8 75 180
BOTTOM HEM SNL 2 0.45 133 213
COMFORT LBL JOIN SNL 1 0.4 150 120
FINAL THREAD CUT HELPER 2 0.4 150 240

Here,

  • IRN – Iron Machine
  • SNL – Single needle lock stitch
  • 3 OL – 3 thread Overlock
  • VERT – Vertical Machine
  • DNL – Double needle lockstitch machine
  • K-S – Kansai machine
  • FOA – Feed of the arm

Operation Breakdown and SMV of Men’s Long Sleeve Shirt excel

Written by

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

Linkedin: A.M. Amirul Islam

Job Responsibilities of Quality AGM or GM in Apparel Industry

Job Responsibilities of Quality AGM or GM in Apparel Industry

Garments Quality GMA quality DGM, AGM or GM is the head of quality in an apparel industry, who is responsible for leading the whole department from the supreme position. It is the top designation of apparel industry like production/operation GM. A quality GM is the utmost responsible person for any quality issues in the apparel industry. It’s very important to know about Quality GM job responsibility for every quality related person as our dream to be Quality GM, highest stage of career. Job Responsibilities of Quality AGM or GM in Apparel Industry is the indicator of what qualification is required to become Quality GM and where the focus is needed.

Job Responsibilities of Quality AGM or GM in Apparel Industry

You may also like to read:

  1. Job responsibilities of a buying house QC
  2. Job Responsibilities of Quality Manager in Apparel Industry
  3. GPQ Job Responsibilities in Apparel Industry

Job Description of Garments Quality AGM or GM

  1. Full responsibility for quality function within the location through the entire manufacturing process including incoming, in the process, section-wise, finished goods inspection, and testing.
  2. Maintains and improves product and operation quality by monitoring product requirements, SOP, compliance and technical support for the factory.
  3. Develops and analyzes statistical data and product specifications to determine present standards and establish proposed quality and reliability expectancy of finished product
  4. Develops and maintains quality assurance and control objectives and coordinates objectives with production procedures in cooperation with the Production Department and others supporting departments.
  5. Develop a plan, promote, facilitate and organizes training activities for all respective person related to product quality and reliability.
  6. Continuously review quality control processes, procedures, and capabilities in order to sustain the most cost-effective and efficient methods for meeting quality requirements and making a recommendation for improvement as appropriate for Garments factory.
  7. Responsible for buyers any quality inspection failing; final inspection, in-process/inline quality audit and inspection.
  8. Responsible for customer (buyer) quality claim and giving on time customer feedback in any quality issue.
  9. Responsible for all Technical Audit and implementation of customer technical requirement.
  10. Should have knowledge of all aspect of quality control methods and practices including AQL levels and other prevailing international standards.
  11. Implement QC tools, lean manufacturing, and quality visualization.

Job Responsibilities of Quality AGM or GM in Apparel Industry pdf

Written by

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

Linkedin: A.M. Amirul Islam

Features of Single Needle Lock Stitch Machine

Features of Single Needle Lock Stitch Machine

Single needle lock stitch machine is called a plain needle sewing machine. Single needle lock stitch machine is mostly used as an industrial sewing machine. Modern single needle lockstitch has a thread trimmer which operates at the highest speed of its kind. Lockstitch machine is the most commonly used sewing machine in the apparel industry, especially in woven garments. Here in this article, I am going to share Features of Single Needle Lock Stitch Machine with you for a clear understanding of single needle lock stitch sewing machine.

Types of Lock stitch Sewing Machine

There are two types of lock stitch sewing machine used in a garments factory.

  1. Single needle lockstitch machine
  2. Double(two) needle lockstitch machine

Single Needle Lock Stitch Machine

Single needle lock stitch machine is stitch by one needle of a machine by lock stitch.

Double Needle Lock Stitch Machine

Double-needle /twin/two needle is a needle with a single shank and two shafts, proceed stitching with the double stitching you will get two parallel rows on the face of the fabric and a zig-zag stitch on the back of the fabric.

You may also love to read:

Parts of Single Needle Lock Stitch Sewing Machine

Different Parts of Single Needle Lock Stitch Sewing Machine

Different Parts of Single Needle Lock Stitch Sewing Machine

  1. Bobbin Winder
  2. Thread wiper device
  3. Lifting lever
  4. Hand swatch A
  5. Hand swatch B
  6. Work Clamp
  7. Knee lifter plate
  8. Power stitch
  9. Oil gauge window
  10. Oil feeding pocket
  11. Machine pulley
  12. Operation panel
  13. Cotton stand
  14. Control box
  15. Power indicator
  16. USB port
  17. Pulley cover
  18. The thread takes up cover
  19. Finger guard

Parts of Single Needle Lock Stitch Sewing Machine

Features of Single Needle Lock Stitch Machine

  1. Two thread need for a machine, one for needle and another one for bobbin
  2. Needle thread set in the upper side of fabric and bobbin thread set in the lower side of the fabric in stitch
  3. Stitching type only lock stitch
  4. Machine speed is 4000-5000 RPM
  5. 1 needle in every machine
  6. Edge cutting, automatic bobbin winding
  7. Less noise, low vibration, no radiation, and environment-friendly
  8. SPI generally 7-9
  9. Sewing Shirts, Jackets, Suits, Over-coats, Bed covers, Curtains, Children’s clothes, Bags, Leather, Wool, Chemical fiber and Canvas.

Features of Single Needle Lock Stitch Machine

Technical Specifications of Lock Stitch Machine

  1. Basic Machine Practice (Loop Exercise)
  2. Technical Specification
  3. Installation of needle
  4. Needle bar Height adjustment
  5. Hook Set Timing
  6. Feed Dog adjustment and alignment
  7. Feed Dog Eccentric cam Adjustment
  8. Pressure foot to the Pressure adjustment

Features of Single Needle Lock Stitch Machine pdf

Written by

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

Linkedin: A.M. Amirul Islam

Job Responsibilities of Garments Buyer QC

Job Responsibilities of Garments Buyer QC

Buying House QC: A buyer QC is a buying house quality controlling representative, an employee of the buyer, work to ship buyer’s required product quality. Here the QC indicates Quality Control. Buying House assign QC for factory final inspection, all other quality audit and maintaining own quality procedure. Buyer QC is highly respected with good hospitality in every apparel industry. Lots of peoples dream job is to be buying house quality inspector, especially for the people who are working in the different quality control department. Buyer QC is the ultimate authorize from person garments buyer to pass the final inspection of finished goods. I made a list of buyer QC Job description in Apparel industry; hopefully, this article will help you to clear your concept about Job Responsibilities of Garments Buyer QC. A QC manager leads all QC of his team in a buying house.

Job Responsibilities of Garments Buyer QC Quality Control

We have two related article you may  also like to read:

The Job Description of Garments Buyer QC

  1. Accomplish QC cycle of a factory by controlling samples; follow up materials production in-house status, control materials in-house testing, organize PP meeting, cutting permission, inspection, reporting & record keeping.
  2. Provide training and educate to the quality & production personnel, maintain the needed quality requirements throughout the production processes strictly following the buyer specifications.
  3. Checking cutting, sewing, and finishing in-process quality control and report to the management.
  4. Understand and follow the quality SOP in each step of the process, Implement buyer’s every work manual & follow the quality standard to the production factory.
  5. Conduct In-line Audit, an in-process audit in sewing, finishing, and packing.
  6. Monitor the whole quality process of the assigned factory.
  7. Final inspection and confirm the quality of the end product.
  8. Train up and lead factory GPQ team directly.
  9. Ultimate responsible person for factory quality controlling process from buyer end.
  10. Highlight quality report to vendor management and his own top management about any types of quality issue.
  11. Send final inspection report to buying-house, reporting boss, send a report to factory and buyer top management in critical quality and inspection issue.

Basic Qualification of a Buying House QC

  1. Minimum 7-10 years’ experience (vary buying-house to Buying House) in apparel manufacturing industry
  2. Understand fabrics, wash, shade, garments measurement, and AQL system
  3. Knowledge of Quality control/Audit, QMS, TQM, QC tools, 5S
  4. Good communication skill; both written and verbal, decision making, problem-solving, good analytical skills, statistical chart, and reporting skill.

Job Description of Buyer Quality Control pdf

Written by

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

Linkedin: A.M. Amirul Islam

List of Machinery and Their Functions of Apparel Industry

List of Machinery and Their Functions of Apparel Industry

Various types of machine use in the apparel industry from Warehouse to finishing. In this article, you will get a list of machinery and their functions of apparel industry.  Hopefully, this list of all the machinery of the apparel industry with their uses will help you to understand the different machine functions. This list contains all types of Garments machinery.

 List of Machine Used in Garments Factory

List of Machine Used in Garments Factory

  1. Fabrics inspection machine
  2. Plotter printing machine
  3. Cutting machine
  4. Fusing machine
  5. Embroidery machine
  6. Sewing machine
  7. Thread Trimmer machine
  8. Thread sucking machine
  9. Iron machine
  10. Pull test machine
  11. Metal detector machine
  12. Barcode scanning machine
  13. Heat seal joining the machine
  14. Case label printing machine
  15. Moisture checking machine
  16. Digital Hygrometer
  17. Air compressor machine
  18. Boiler machine
  19. Generator
  20. Water pump

List of Machinery and Their Functions of Apparel Industry

Functions of Machinery Used in Garments

List of Machinery and Their Functions of Apparel Industry
SL Name of Machine Functions of Machine Using department
1 Fabrics inspection machine Use to do fabrics inspection to check fabrics defects Fabrics inspection
2 Plotter printing machine Print Garments marker CAD
3 Cutting machine Cut fabrics as per marker Cutting
4 Fusing machine Fuse interlining Fusing-Sewing
5 Embroidery machine To set Embroidery in garments Embroidery
6 Sewing machine Sew garments Sewing
7 Thread Trimmer machine Thread trimming of garments uncut thread Finishing
8 Thread sucking machine Reduce loose and unnecessary thread from garments. Finishing
9 Iron machine Pressing garments to get good appearances Finishing
10 Pull test machine To determine the pulling strength of any type of button Finishing
11 Metal detector machine o get a metal-free final product in carton Packing and Finishing
12 Barcode scanning machine Scan sticker and ticketing of garments Finishing
13 Heat seal joining machine Set up heat seal label in Garments Finishing
14 Case label printing machine Print case label of garments carton Merchandising-Packing
15 Moisture checking machine Find out moisture percentage of finished garments Packing
16 Digital Hygrometer Determine  RH% for every section All section-specially warehouse
17 Air compressor machine Produce compressed air for machine and maintenance department Utility section
18 Boiler machine Generate hot steam for Iron machine Utility section
19 Generator Produce electricity Utility section
20 Water pump Pick water for factory Utility section

List of Machinery and their functions of the apparel industry pdf

Written by

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

Linkedin: A.M. Amirul Islam