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 Types, Specifications and Technical Adjustment
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
2 Thread Overlock machine
3 Thread Overlock Machine
4 Thread Overlock Machine
5 Thread Overlock Machine
6 Thread Overlock Machine
The Relationship between Overlock Machine and Number of Thread Used
No. Of Threads use
Total threads use
2 Thread Overlock Machine
3 Thread Overlock Machine
4 Thread Overlock Machine
5 Thread Overlock Machine
6 Thread Overlock Machine
Features of Overlock Sewing Machine
Maximum Machine speed 6500 SPM (vary operation wise)
Stitch can be made using 2,3,4,5 or 6 threads, depending on the no. of needles and looper
Stitch length 2 to 4 mm
Stitching type- Overlock stitch
Used feed is Deferential feed
Oil lubrication system- Automatic
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.
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.
Benefits of Production Planning in the Apparel Industry
Keeping a sequence of production order
Estimating production as per line wise capacity
Achieving targeted production
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.
Fabrics, trims, and accessories in-house status
Fabrics, trims and accessories inventory and inspection report
These factors are key to develop a production plan for the apparel industry.
Price of every single unit Garments
Current Production status
Planned final audit date
Goods input date to sewing
Planned Capacity / Day / Line
Number of Lines
Name of a line for production
Weekend / Holidays during prod
No of Working Day Required of every style
Sewing Output Finish Date
Wash Input Date
Planned Capacity Per Day of washing
Production Unit of washing
No of Working Day Required to complete washing
Wash Completing date
Dry Process; apply or not apply
Goods Finishing Start Date
Planned Capacity Per Day of finishing
Weekend/Holiday during production in finishing
No of Working Day Required to complete finishing
Goods Will Ready for final Audit
Factory Wise Planned Production Capacity Sewing
No Of line /Production Unit in the facility
Factory Wise Planned Production Capacity Wash
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.
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 Procedure in Buying House
Submit the Color Continuity Cards to QC/Wash or fabrics QC or merchandisers.
Buying house is responsible for the sign off of Color Continuity Cards.
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.
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.
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.
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.
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.
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.
Generally, 4 sets of Shade Band approve by buying house, 1 keeping in buying house, 1 for wash factory and two for garments maker
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.
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.
List of Inventories in Textile and Garments Industry
Raw Materials (Yarn, Dyes Chemicals, Packing Materials, Trims and Accessories etc.)
Semi Processed Materials (Gray Fabric)
Finished Goods (Garments Products)
General Guidelines of Inventory Management in Apparel Industry
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.
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.
Calculate reorder point: Place order when inventory stock reaches to a particular level.
Calculate lead time and make a decision: Calculate how much time is required to place an order and receiving those goods to the factory.
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.
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.
A proper record should be kept both manual (bin card, registry book), and computer-based database.
Every issues and receive must be recorded properly
Ensure a good warehouse condition for inventories so that no bug can spoil your valuable materials.
Proper inventory valuation method needs to be used and keep records of all valuation data
Inventories of different level should be kept in separate room or areas so it is not mixed-up
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.
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 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
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.
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 of Men’s Long Sleeve Shirt
Operation Breakdown for Garments Manufacturing: Operation 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.
Job Responsibilities of Quality AGM or GM in Apparel Industry
Garments Quality GM: A 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.
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.
Maintains and improves product and operation quality by monitoring product requirements, SOP, compliance and technical support for the factory.
Develops and analyzes statistical data and product specifications to determine present standards and establish proposed quality and reliability expectancy of finished product
Develops and maintains quality assurance and control objectives and coordinates objectives with production procedures in cooperation with the Production Department and others supporting departments.
Develop a plan, promote, facilitate and organizes training activities for all respective person related to product quality and reliability.
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.
Responsible for buyers any quality inspection failing; final inspection, in-process/inline quality audit and inspection.
Responsible for customer (buyer) quality claim and giving on time customer feedback in any quality issue.
Responsible for all Technical Audit and implementation of customer technical requirement.
Should have knowledge of all aspect of quality control methods and practices including AQL levels and other prevailing international standards.
Implement QC tools, lean manufacturing, and quality visualization.