Category: Industrial Engineering (IE)

One Comment

Standard Minute Value: SMV in Garments, Calculation, Importance

  By , ,

Standard Minute Value: SMV in Garments, Calculation, Importance

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

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

Standard Minute Value - SMV in Garments, Calculation, Importance

The prime objective of industrial engineering is:

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

Importance of SMV in the Apparel Industry

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

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

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

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

Formulas of Calculating SMV

SMV in Garments Formula

Calculation of SMV in Garments

SMV = (Basic Time + Allocated Allowance)

The formula of Basic Time = Observe Time x Rating Factor

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

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

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

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

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

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

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

Example of Calculation of SMV in Garments

Suppose for making a product the following assumption is there

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

Basic Time = 25minutes x 80% = 20 minutes

Allowance = 20 x 10% = 2 Minute

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

Calculation of Capacity of Single Operator in Garments

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

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

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

Calculation of Efficiency Percent

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

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

whereas the target was,

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

SMV of Different Types of Garments Manufacturing

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

Written by

Md. Nahian Mahmud Shaikat

No comments

Operation Breakdown, SMV and Layout of Blouse Manufacturing

  By ,

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: amirul.washim7[email protected]

Linkedin: A.M. Amirul Islam

No comments

Visual Management System in Apparel Industry

  By ,

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

No comments

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

  By ,

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 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 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 total 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 have 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

No comments

Kanban Board in Garments Manufacturing Production Floor

  By , ,

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

No comments

Operation breakdown, SMV and Layout of Leggings

  By ,

Operation Breakdown, SMV and Layout of Leggings

Leggings are tight fit bottom wear, typically preferred by the women but men can wear. Legging is high stretchable knitwear garments, wears with Kurti, very much comfortable, made by blended Lycra fabrics (Spandex). Leggings total sewing SMV is 4.64, 15 manpower needed approximately and 14 sewing machine will be needed. Here is the Operation breakdown, SMV and Layout of Leggings, hopefully, this will help you to know the SMV of Leggings.

Sewing Operation Breakdown, SMV and Layout of Leggings Manufacturing

TOTAL SMV 4.64 TARGET AT
Total Manpower 15
Number of Operators 13 60% 113
Number of A.O.P 2 70% 131
Number of IRON 80% 150
Sl Operation Description SMV Manual/ M/c M/C OP/ AOP Balancing Tgt/Hr Tot.Tgt/Hr Var. Operation Request
1 Care label cut & attach 0.2 SNL 1 0.5 300 150 136
2 Front rise join with sticker match 0.25 4OL 1 0.5 240 120 108
3 Back rise join 0.22 4OL 1 0.5 273 136 134
4 Inseam join 0.45 4OL 2 2 133 267 267
5 Waist belt Tape & Elastic open give steam & cut 0.3 MNL 1 200 200 200
6 Elastic ring make & mark 0.3 SNL 1 1 200 200
7 West belt make & mark 0.35 SNL 1 2 171 343 343
8 Elastic tk with belt 0.4 SNL 1 1 150 150 150
9 Body mark & tape attach with belt 0.3 SNL 1 1 200 200 200
10 West belt attaches at the waist 0.6 4OL 2 2 100 200 200
11 Label attach 2 0.25 SNL 1 0.5 240 120 118
12 Leg Hem 0.45 FL 1 1 133 133 132
13 Crosspoint BTK 0.12 BT 1 0.5 500 250 249
14 FINAL THREAD CUT & STICKER REMOVE 0.45 MNL 1 133 133 131
Total SMV 4.64 Total MP   14.5          

Summary

SL NO   MACHINE NAME M/C QTY
1 SNL Single Needle Lock Stitch M/c 6
2 4OL 4 Thread Over Lock M/c 6
3 FL Flat Lock M/c 1
4 BT Bartack M/c 1
TOTAL QTY 14

Operation Breakdown, SMV and Layout of Leggings

Written by

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

Linkedin: A.M. Amirul Islam

No comments

Operation Bulletin and SMV of a Nano Chino Pant

  By ,

Operation Bulletin and SMV of a Nano Chino Pant

I have written this article so that you can have a good idea of Operation Bulletin and SMV of a Nano Chino Pant. Here Total SAM is 28.93 and 92 manpower needed for Nano chino pant. Operation breakdown, manpower, machine, and production target given in below.

Operation Bulletin and SMV of a Nano Chino Pant
Style Name & NO :   SAM Avg 10%+ 0.35 Max 0.36
Buyer:   28.93 0.32 10%- 0.28 Min 0.24
Description: NANO CHINO Efficiency 70% 80% 85% 90%
Tar/Hr 133 152 161 171
S/N M/C Guide/Presser foot Folder Section Operation SAM Tar/Hr TAKT Man Power Remarks
1 IRON Patch W/B fuse 0.28 214 0.28 1
2 BLIND Loop make 0.36 167 0.36 1
3 SNLS 24 mm Single fly binding 0.16 375 0.32 0.5
5 SNLS CR 1/16 guide Front pocket Facing join-large 0.31 194 0.31 1
6 SNLS CR 1/16 guide Front pocket Facing join-small 0.31 194 0.31 1
7 SNLS CR 1/16 guide Mini pocket Join 0.32 188 0.32 1
8 HP W/B & contrast mark & cut 0.31 194 0.31 1
9 SNLS Hanger guide W/B contrast join 0.35 171 0.35 1
10 IRON Pesting press at w/b 0.36 167 0.36 1
11 SNLS CR 1/16 guide Size label join 0.34 176 0.34 1
12 SNLS Ordinary guide Care label join 0.34 176 0.34 1
13 HP Back Mark welt pocket Position 0.24 250 0.24 1
14 3OL Back panel serging 0.57 105 0.29 2 Serging machine
15 SNLS CR 1/16 guide Welt pocket Facing join 0.31 194 0.31 1
16 SNLS Ordinary guide Back dart make 0.33 182 0.33 1
17 IRON Back dart & bon press 0.32 188 0.32 1
18 APW Welt pocket Make 0.33 182 0.33 1
19 HP Welt pocket Corner cut 0.3 200 0.3 1
20 HP Match front & back panel 0.3 200 0.3 1
21 SNLS Ordinary guide Welt pocket Corner tack 0.33 182 0.33 1
22 SNLS CR 1/16 guide Facing close 0.32 188 0.32 1
23 IRON Welt pocket Press 0.55 109 0.28 2
24 SNLS Ordinary guide Keyhole tack 0.3 200 0.3 1
25 KH Keyhole make 0.32 188 0.32 1
26 EC Ordinary guide Back pocket Bag close 0.71 85 0.36 2
27 SNLS Zipper guide Back pocket inner stitch 0.31 194 0.31 1
28 SNLS CR 1/4 guide Back pocket Bag t/s 0.61 98 0.31 2
29 SNLS CR 1/16 guide Main label join 0.33 182 0.33 1
30 SNLS Ordinary guide FRONT Coin pocket join 0.34 176 0.34 1
31 SNLS Ordinary guide Front pocket Join 0.34 176 0.34 1
32 5OL Coin pocket Ol 0.31 194 0.31 1
33 SNLS Ordinary guide Coin pocket Tack 0.31 194 0.31 1
34 SNLS CR 1/16 guide Front pocket Edge stitch 0.33 182 0.33 1
35 EC Ordinary guide Front pocket Bag close 0.32 188 0.32 1
36 SNLS CR 1/4 guide Front pocket Bag t/s 0.33 182 0.33 1
37 SNLS Ordinary guide Front pocket Tack side & waist-Right 0.31 194 0.31 1
38 SNLS Ordinary guide Front pocket Tack side & waist-Left 0.31 194 0.31 1
39 SNLS Ordinary guide Double fly make & coin pocket Rolling 0.33 182 0.33 1
40 3OL Front rise & fly ol 0.34 176 0.34 1
41 SNLS CR 1/16 guide Single fly join & t/s 0.32 188 0.32 1
42 IRON Fly press 0.31 194 0.31 1
43 SNLS CR 1/16 guide Zipper join 0.32 188 0.32 1
44 SNLS Zipper guide Double fly join 0.34 176 0.34 1
45 SNLS CR 1/16 guide Zipper t/s 0.31 194 0.31 1
46 SNLS Ordinary guide Front rise tack 0.32 188 0.32 1
47 SNLS Ordinary guide J-stitch make 0.31 194 0.31 1
48 HP Assembly Back panel opening mark 0.31 194 0.31 1
49 HP Front panel opening mark 0.31 194 0.31 1
50 3OL Front panel ol 0.68 88 0.34 2
51 SNCS Side seam join 0.89 67 0.3 3
52 IRON Front pocket Linning press 0.31 194 0.31 1
53 IRON Btm. Hem press 0.31 194 0.31 1
54 SNLS Ordinary guide Front pkt.tack with inseam 0.3 200 0.3 1
55 SNLS Ordinary guide Front pocket Lining close-left 0.31 194 0.31 1
56 SNLS Ordinary guide Front pocket Lining close-right 0.31 194 0.31 1
57 BARTACK Back welt pocket & coin pocket Bartack- 6 points 0.33 182 0.33 1
58 SNCS Inseam join 0.68 88 0.34 2
59 SNLS Ordinary guide Crosspoint tack 0.32 188 0.32 1
60 DNCS Back rise join 0.33 182 0.33 1 Tandom
61 SNLS Ordinary guide Back panel hidden stitch 0.32 188 0.32 1
62 HP W/B & loop match 0.32 188 0.32 1
63 SNLS Ordinary guide Loop join 0.65 92 0.33 2 Laser light
64 EC Ordinary guide W/B join 0.88 68 0.29 3
65 HP Turn body 0.31 194 0.31 1
66 HP Mark hook & bar position 0.31 194 0.31 1
67 H & B Att. hook & bar 0.31 194 0.31 1
68 SNLS Ordinary guide Main label join 0.31 194 0.31 1
70 SNLS Ordinary guide Mouth close -upper 0.33 182 0.33 1
71 SNLS Ordinary guide Mouth close -lower 0.33 182 0.33 1
72 SNLS Ordinary guide Mouth t/s 0.33 182 0.33 1
73 SNLS Needle feed W/B close 0.64 94 0.32 2
74 SNLS CR 1/16 guide Double fly t/s 0.34 176 0.34 1
75 BARTACK Loop down & cross point bartack-6 points 0.33 182 0.33 1
76 BARTACK Loop & front pocket bag bartack-7 points 0.61 98 0.31 2
77 BARTACK Contrast tack-4 points 0.32 188 0.32 1
78 HP Thread cut 0.32 188 0.32 1
79 BARTACK Front pocket & fly bartack-6 points 0.34 176 0.34 1
80 SNLS G guide Btm. Hem rolling 0.52 115 0.26 2
Total 28.93 176 24.8 92  

Machine and operator summary of Sewing operation breakdown

M/C No of Operator
SNLS 45.5
DNCS 1
APW 1
5OL 1
3OL 5
EC 6
KH 1
H & B 1
BARTACK 6
BLIND 1
DIS 0
SNCS 5
HP 10
IRON 8
Total 91.5

Here,

  • SNLS – Single needle lockstitch Machine
  • DNCS- Double-needle chain stitch machine
  • APW – APW Bone machine
  • 5OL –  5 Thread overlock machine
  • 3OL – 3 Thread overlock machine
  • KH – Kansai machine
  • BARTACK – Bartack Machine
  • BLIND – Blindstitch Machine
  • SNCS – Single needle chain stitch machine
  • HP – Helper
  • IRON – Iron Machine

Layout Graph of sewing operation breakdown

Operation Bulletin and SMV of a Nano Chino Pant

Written by

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

Linkedin: A.M. Amirul Islam

No comments

Operation Breakdown and SMV of a Men’s Chino Pant

  By ,

Operation Breakdown and SMV of a Men’s Chino Pant

Chino pants are made by twill fabric, made of 100% cotton, in stylish and fashionable for men, could produce in different colors. Chino pant can be both long and short types, long are commonly used, to be worn as part of a formal outfit. Peoples can wear it as a casual, semi-casual and formal dress. Here total SMV is 24.15 and 85 sewing machine needed. Here in this article, you will have details of Operation Breakdown and SMV of a Men’s Chino Pant.

Operation Breakdown and SMV of a Men’s Chino Pant

Operation Bulletin and SMV of a Men’s Chino Pant

Operation Breakdown/Bulletin and SMV of a Men’s Chino Pant
SL NO OPERATION Machine No. of Machine SMV Target @ 100% efficiency Target @ 80% efficiency
FRONT PART
1 FNT  FLY FUSING IRN 1 0.2 300 240
2 FNT PART KNEE MARK H 1 0.25 240 192
3 SEAM + COIN PKT MARK H 1 0.35 171 137
4 COIN  BK PKT ROLLING DNL 1 0.3 200 160
5 COIN PKT JOIN & 2ND STC SNL 1 0.15 400 320
6 SEAM I/R IRN 1 0.25 240 192
7 S/FLY+ D/FLY+ FNT RISE SERGING 3OL 1 0.35 171 137
8 THREAT CUT H 1 0.5 120 96
9 FNT PKT FACING JOIN SNL 1 0.25 240 192
10 FNT PKT SEAM JOIN SNL 1 0.25 240 192
11 FNT PKT JOIN SNL 1 0.25 240 192
12 FNT PKT MOUTH ROLLING DNL 1 0.3 200 160
13 THREAD CUT HP 1 0.6 100 80
14 FNT FNT TACK ( HORI.VS VERTICAL) SNL 1 0.4 150 120
15 FNT PKT BAG SERGING 3OL 1 0.75 80 64
17 FNT  PKT BAG  TOP 1/4 SNL 1 0.35 171 137
18 S/FLY JOIN+T/S SNL 1 0.2 300 240
19 ZIPPER JOIN SNL 1 0.35 171 137
20 J-TOP STC MARK H 1 0.25 240 192
21 J-TOP STC DNL 1 0.4 150 120
22 D/FLY JOIN SNL 1 0.35 171 137
23 ZIPPER CLOSE SNL 1 0.25 240 192
24 ZIPPER T/S SNL 1 0.25 240 192
25 FNT RISE T/S DNL 1 0.25 240 192
26 FNT PART WAIST MARK HP 1 0.25 240 192
27 BTM LEG ZIPPER O/L 3OL 1 0.25 240 192
28 0.25 240 0
29 FNT PART CHEACK
30 BK PART 
31 FNT PART KNEE MARK H 1 0.2 300 240
32 BK PART DART+ BON JOIN MARK H 2 0.5 120 192
33 BK BON FACING SERGING 3 OL 1 0.3 200 160
34 BK PART DERT MAKE SNL 1 0.35 171 137
35 BK PART TACK+ BK PKING TACK SNL 1 0.4 150 120
36 BON ROLLING SNL 1 0.3 200 160
37 BON MACHING +BON LENGHT MARK H 2 0.4 150 240
38 BK BON CREASING IRN 2 0.4 150 240
39 BK BON JOIN DNL 2 0.6 100 160
40 BON CUT + TURN OVER H 2 0.5 120 192
41 BON TOP STC DOWN SIDE SNL 3 0.9 67 160
42 BON TOP STC UPPER SIDE SNL 2 0.6 100 160
43 BK BON PKT INSIDE TACK SNL 2 0.45 133 213
44 BK BON PKT BAG SERGING 3 OL 1 0.3 200 160
45 BK BON  PKT BAG 1/4 STC SNL 1 0.3 200 160
46 BK RISE JOIN 5 OL 1 0.25 240 192
47 BK RISE TOP STC FOA 1 0.3 200 160
48 FNT PART MARK H/P 1 0.2 300 240
49 BK PART CHEACK QC
50 ASSEMBLY
51 FNT+ Bk PART MATCHING H 1 0.3 200 160
52 SIDESEAM JOIN 5 OL 2 0.5 120 192
53 CARE LBL MAKE +JOIN SNL 1 0.4 150 120
54 SIDE SEAM SAFETY STC SNL 2 0.5 120 192
55 INSEAM JOIN 5 OL 2 0.45 133 213
56 W/BELT FUSING IRN 1 0.2 300 240
57 W/BELT PIPING ATT SNL 1 0.3 200 160
58 W/BELT HOLE HOLE 1 0.3 200 160
59 W/BELT BTN ATTACH BUTTON 1 0.3 200 160
60 LOOP MAKE +ASSEMBLY FL 1 0.3 200 160
61 LOOP CUT+ATTACH MARK H 1 0.3 200 160
62 LOOP JOIN SNL 2 0.5 120 192
63 W/BELT ATTACH MARK H 2 0.3 200 320
64 W/BELT MATCHING H 1 0.2 300 240
65 SIDE SEAM OPENING MARK H 1 0.2 300 240
66 W/BELT JOIN K-S 2 0.5 120 192
67 W/BELT MOUTH CUT+TREAD REMOVE H 1 0.4 150 120
68 W/BELT MOUTH MARK H 1 0.25 240 192
69 W/BELT MOUTH CLOSE SNL 3 0.8 75 180
70 LOOP DEEP TACK SNL 2 0.45 133 213
71 BTM HEM ROLLING SNL 2 0.6 100 160
72 THREAD CUT H 2 0.3 200 320
73 FINAL TABLE QC
TOTAL   85 24.15  

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
  • H – Helper

Written by

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

Linkedin: A.M. Amirul Islam

No comments

Operation Breakdown and SMV of a Cargo Crop Pant

  By ,

Operation Breakdown and SMV of a Cargo Crop Pant

Adding cargo pocket in crop pant, we call it cargo crop pant, for better understanding please have a look at the picture given below.  As per this, this breakdown to SMV is 30.74, manpower needed 95, given operation sequence wise breakdown to understand and set up sewing line layout of a Cargo crop pant. Crop pant is very fashion and popular in this era, everyone wears it as casual and semi-casual wear. In this article, you will have details of Operation Breakdown and SMV of a Cargo Crop Pant.

Operation breakdown and SMV of a Cargo crop pant

Operation Breakdown/Operation Bulletin and SMV of a Cargo Crop Pant 
Style Name & NO : SMV Avg 10%+ 0.36 Max 0.72
Buyer: 30.74 0.32 10%- 0.29 Min 0.21
Description: CARGO CROP PANT Efficiency 60% 65% 70% 75%
Tar/Hr 111 121 130 139
S/N M/C Section Operation SMV Tar/Hr TAKT Man Power Remarks
1 HP Patch mark at coin pocket  Facing 0.25 240 0.25 1
2 3OL o/l coin pocket  & front pocket  Facing 0.32 188 0.32 1
3 SNLS coin pocket  Tack 0.28 214 0.28 1
4 SNLS join coin pocket Facing with lining 0.32 188 0.32 1
5 SNLS decorative stitch at coin pocket 0.31 194 0.31 1
6 DNLS make coin pocket  & front pocket 0.36 167 0.36 1
7 HP mark at w/b inner 0.28 214 0.28 1
8 SNLS tack w/b inner 0.36 167 0.36 1
9 SNLS tack w/b upper 0.35 171 0.35 1
10 KAN dummy stitch at w/b upper 0.36 167 0.72 0.5
11 HP mark at w/b upper 0.26 231 0.26 1
12 IRON 1/16 iron w/b upper 0.42 143 0.42 1
13 SNLS tack w/b inner & upper 0.39 154 0.39 1
14 EC join w/b inner & upper 0.38 158 0.38 1
15 SNCS t/s at w/b 0.75 80 0.38 2
16 IRON press at w/b 0.58 103 0.29 2
17 SNLS the main label join at w/b 0.29 207 0.29 1
18 SNLS size  label join at w/b 0.28 214 0.28 1
19 BLIND loop make 0.25 240 0.5 0.5
20 SNLS Back stay stitch at back yoke 0.37 162 0.37 1
21 5OL back yoke join 0.38 158 0.38 1
22 DNCS back yoke t/s 0.39 154 0.39 1
23 5OL back rise join 0.38 158 0.38 1
24 DNCS back rise t/s 0.36 167 0.36 1
25 SNCS back pocket Rolling 0.32 188 0.32 1
26 IRON back pocket  Iron 0.45 133 0.23 2
27 HP mark back pocket  Position 0.29 207 0.29 1
28 HP scissor at back pocket  & match with the body 0.28 214 0.28 1
29 HP match front & back part 0.25 240 0.25 1
30 DNLS back pocket  Join 0.98 61 0.33 3
31 HP mark at back yoke & knee 0.28 214 0.28 1
32 3OL back part o/l 0.36 167 0.36 1
33 HP Front mark at the front part 0.32 188 0.32 1
34 EC front pocket  Lining join 0.38 158 0.38 1
35 DNLS front pocket  Mouth t/s 0.66 91 0.33 2
36 IRON front pocket  Mouth press 0.26 231 0.26 1
37 EC front pocket  Join 0.78 77 0.39 2
38 SNLS t/s at front pocket 0.31 194 0.31 1
39 SNLS front pocket Tack side & waist 0.68 88 0.34 2
40 3OL o/l front rise, fly & fly box 0.34 176 0.34 1
41 SNLS single fly join & edge stitch 0.36 167 0.36 1
42 SNLS zipper join with a single fly 0.35 171 0.35 1
43 SNLS J-stitch make 0.36 167 0.36 1
44 SNLS J-stitch t/s 0.36 167 0.36 1
45 SNLS join double fly with zipper & front rise 0.32 188 0.32 1
46 SNLS zipper join with double fly 0.28 214 0.28 1
47 SNLS front rise tack 0.29 207 0.29 1
48 SNLS front rise t/s 0.23 261 0.23 1
49 HP front pocket Opening mark 0.28 214 0.28 1
50 3OL front part o/l 0.38 158 0.38 1
51 SNLS tack at inseam point 0.31 194 0.31 1
52 5OL Assemble inseam join 0.69 87 0.35 2
53 FOA inseam t/s 0.37 162 0.37 1
54 IRON Press bottom Hem 0.28 214 0.28 1
55 BARTACK bartack at back pkt. & fly (5) 0.36 167 0.36 1
56 SNLS side seam tack 0.34 176 0.34 1
57 SNCS side seam close 0.72 83 0.36 2
58 SNLS side seam tack & care label join 0.28 214 0.28 1
59 DNLS cord stitch 0.42 143 0.21 2
60 HP mark at the back part 0.29 207 0.29 1
61 HP match belt with body 0.28 214 0.28 1
62 EC w/b join 0.82 73 0.27 3
63 HP turn body 0.32 188 0.32 1
64 SNLS w/b tack 0.65 92 0.33 2
65 FOA w/b down t/s 0.75 80 0.38 2
66 SNLS mouth close-upper 0.38 158 0.38 1
67 SNLS mouth close-lower 0.38 158 0.38 1
68 HP mark loop position 0.28 214 0.28 1
69 HP cut & match loop with body 0.27 222 0.27 1
70 SNLS loop join 0.82 73 0.27 3
71 BARTACK loop, cord stitch edge & fly bartack (13) 0.7 86 0.35 2
72 SNLS bottom hem tack 0.32 188 0.32 1
73 SNCS make bottom hem 0.82 73 0.41 2
74 SNLS bottom hem tack 0.31 194 0.31 1
75 HP turn body 0.22 273 0.22 1
76 HP thread cut 0.28 214 0.28 1
77 HP sticker remove 0.26 231 0.26 1
Total 30.74 171 25.28 95

 

Operation Breakdown Bulletin and SMV of a Cargo Crop Pant

You may like, List of the Sewing machine used in the Apparel industry

Machine and operator summary of sewing Line

M/C No. of Operator
SNLS 32
DNCS 2
DNLS 8
5OL 4
3OL 4
EC 7
FOA 3
KAN 0.5
BARTACK 3
BLIND 0.5
SNCS 7
HP 17
IRON 7
Total 95

Here,

  • SNLS – Single needle lockstitch Machine
  • DNCS – Double-needle chain stitch machine
  • DNLS – Double needle lock stitch Machine
  • 5OL – 5 Thread overlock machine
  • 3OL – 3 Thread Overlock Machine
  • FOA – Feed of the Arm Machine
  • KAN – Kansa sewing machine
  • BARTACK – Bartck Machine
  • BLIND – Blind stitch sewing machine
  • SNCS – Single needle chain stitch machine
  • HP – Helper
  • IRON – Iron Machine

Layout Graph

Layout Graph

Written by

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

Linkedin: A.M. Amirul Islam

No comments

Operation Breakdown and SMV of Cargo Short Pant without Bone Pocket

  By ,

Operation Breakdown and SMV of Cargo Short Pant without Bone Pocket

Cargo short pant without bone pocket, use patch pocket instead of Bone Pocket and cargo pocket placed in side-seam position. This article has size-wise SMV, SMV increase as waist size increase, less SMV than bone cargo short pant. Hopefully, after reading you will have details ideas of sizewise Operation Breakdown and SMV of Cargo Short Pant without Bone Pocket.

Operation Breakdown and SMV of Cargo Short Pant without Bone Pocket

Operation Breakdown and SMV of Cargo Short Pant without Bone Pocket
SL Operation Description Aux Time Size wise SMV
Size_29 Size_30 Size_32 Size_33 Size_34 Size_36 Size_38 Size_40 Size_42 Size_44 Size_46 Size_48
1 Small part input Pkt 1.5 0.17 0.17 0.17 0.17 0.17 0.17 0.17 0.17 0.17 0.17 0.17 0.17
2 Atach2 vlcro to c PKT Flp 1.338 0.39 0.39 0.39 0.39 0.39 0.39 0.39 0.39 0.39 0.39 0.39 0.39
3 Crease Cargo Pkt Flap 1 0.8 0.8 0.8 0.8 0.82 0.82 0.82 0.82 0.85 0.85 0.85 0.85
4 Crease hip pkt 1 0.75 0.75 0.75 0.75 0.76 0.76 0.76 0.76 0.76 0.76 0.76 0.76
5 Form & Top sts  Cargo Flp 0.8958 0.759 0.759 0.759 0.759 0.772 0.772 0.772 0.793 0.793 0.793 0.793 0.793
6 Deco Cargo Flap 1.2 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3
7 Set cell pkt to R C flp 1.15 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4
8 Set lbl to C.flap 1.2 0.2376 0.2376 0.2376 0.2376 0.2376 0.2376 0.2376 0.2376 0.2376 0.2376 0.2376 0.2376
9 Serge Left Fly 1 0.088 0.088 0.088 0.088 0.088 0.088 0.088 0.088 0.088 0.088 0.088 0.088
10 Attach Zipper to Left Fly 1 0.246 0.246 0.246 0.246 0.246 0.246 0.246 0.26 0.26 0.27 0.27 0.28
11 1N Hem Rt Fly 1 0.16 0.16 0.16 0.16 0.16 0.16 0.16 0.16 0.17 0.17 0.17 0.17
12 Fold & atach r/fly with l/fly 0.993 0.24 0.24 0.24 0.25 0.25 0.25 0.26 0.26 0.26 0.26 0.27 0.27
13 Set Facing to Wht Pkt 2.072 0.276 0.276 0.276 0.276 0.276 0.276 0.276 0.276 0.276 0.276 0.276 0.276
14 Close Wht Pkt 1.334 0.28 0.28 0.28 0.28 0.28 0.28 0.28 0.28 0.28 0.28 0.28 0.28
15 Tack Wht Pkt 1.334 0.218 0.218 0.218 0.218 0.218 0.218 0.218 0.218 0.218 0.218 0.218 0.218
16 1N Hem cargo pkt 1.4 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
17 Set mbl pkt to R cargo pkt 1.5 0.7 0.7 0.7 0.7 0.72 0.72 0.72 0.72 0.75 0.75 0.75 0.77
18 Top sts Cargo Pkt Bellow 0.896 0.507 0.507 0.507 0.507 0.507 0.513 0.513 0.513 0.519 0.519 0.519 0.519
19 Atach velco to Cargo Pkt 0.8958 0.42 0.42 0.42 0.42 0.44 0.44 0.44 0.44 0.44 0.46 0.46 0.46
20 2N Hem R mbl pkt 1.1 0.223 0.223 0.223 0.223 0.223 0.223 0.223 0.223 0.223 0.223 0.223 0.223
21 Stay Cargo Pkt eight Pleat 0.8958 0.33 0.33 0.33 0.33 0.33 0.33 0.33 0.33 0.35 0.35 0.35 0.35
22 Tack chess pkt & Crgo pkt pleat 0.8958 0.2495 0.2495 0.2495 0.2495 0.2495 0.2495 0.2495 0.2495 0.2495 0.2495 0.2495 0.2495
23 Input Fly and Zipper 1.5 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03
24 Hem Hip Pkt 0.8958 0.41 0.41 0.41 0.41 0.41 0.41 0.43 0.43 0.43 0.43 0.43 0.43
25 Input Fnt,Bk part & Wht pkt 1 0.13 0.13 0.13 0.13 0.13 0.13 0.13 0.13 0.13 0.13 0.13 0.13
26 Set Front Pkt 1.9 0.54 0.54 0.54 0.54 0.56 0.56 0.56 0.56 0.59 0.59 0.59 0.59
27 Blank
28 Set Lf Fly 1.37 0.233 0.233 0.233 0.24 0.24 0.24 0.24 0.24 0.25 0.25 0.25 0.25
29 J-Stitch Fly 1.5 0.249 0.249 0.26 0.26 0.26 0.28 0.28 0.28 0.28 0.28 0.3 0.3
30 Set Rt Fly and Join Crotch 2.1 0.55 0.55 0.57 0.57 0.57 0.57 0.57 0.57 0.57 0.58 0.58 0.58
31 1N Tack Front Pkt 0.896 0.543 0.543 0.543 0.543 0.543 0.565 0.565 0.565 0.565 0.565 0.565 0.565
32 Tack fly & label 1.595 0.24 0.24 0.24 0.24 0.24 0.24 0.24 0.24 0.24 0.24 0.24 0.24
33 2N Set Hip Pkt 0.9167 1.273 1.273 1.273 1.273 1.273 1.273 1.273 1.273 1.273 1.273 1.273 1.273
34 Attach Riser 1.879 0.42 0.42 0.42 0.42 0.42 0.44 0.44 0.44 0.46 0.46 0.46 0.46
35 Fullfell Seatseam 1.458 0.36 0.36 0.36 0.36 0.365 0.37 0.37 0.37 0.38 0.38 0.4 0.4
36 Tack Hip Pkt 1 0.24 0.24 0.24 0.24 0.24 0.24 0.24 0.24 0.24 0.24 0.24 0.24
37 Mark Back pkt position 0.8 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2
38 Safety Stitch Outseam 1.8 0.62 0.62 0.62 0.62 0.62 0.62 0.62 0.62 0.64 0.64 0.64 0.64
39 TopStitch Outseam 1.312 0.5 0.5 0.5 0.5 0.52 0.52 0.52 0.52 0.54 0.54 0.54 0.54
40 Input Cargo pkt,Flap,Wst Bnd 1 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12
41 Set Mobile pkt 1.2 0.75 0.75 0.75 0.75 0.75 0.75 0.78 0.78 0.78 0.8 0.8 0.8
42 Set Cargo Pkt Flap 1 0.95 0.95 0.95 0.95 0.95 0.95 0.98 0.98 0.98 0.98 1 1
43 2N Set Cargo pkt 1.5 1.65 1.65 1.65 1.65 1.68 1.68 1.68 1.68 1.71 1.71 1.71 1.71
44 1N Set Cargo pkt 1.2 0.75 0.75 0.75 0.75 0.75 0.78 0.78 0.78 0.78 0.78 0.8 0.8
45 Tack Cargo, Mbl Pkt & Flap 1 0.58 0.58 0.58 0.6 0.6 0.6 0.6 0.62 0.62 0.62 0.62 0.62
46 Safety Stitch Inseam 1.247 0.44 0.44 0.46 0.46 0.46 0.48 0.48 0.48 0.48 0.5 0.5 0.5
47 Attach Band 2.787 0.38 0.38 0.38 0.38 0.385 0.385 0.385 0.395 0.395 0.395 0.395 0.395
48 Cut thread WB 0.8 0.18 0.18 0.18 0.18 0.18 0.18 0.18 0.18 0.18 0.18 0.18 0.18
49 Unstitch Band 1 0.37 0.37 0.37 0.37 0.37 0.37 0.37 0.37 0.37 0.37 0.37 0.37
50 Finish Band End 1.471 0.72 0.72 0.72 0.72 0.72 0.725 0.725 0.725 0.725 0.729 0.729 0.729
51 1N Hem Bottom 1.58 0.78 0.78 0.78 0.78 0.78 0.81 0.81 0.81 0.81 0.83 0.83 0.83
52 Make Loop 1.78 0.135 0.135 0.135 0.135 0.16 0.16 0.16 0.16 0.16 0.16 0.185 0.185
53 Tack loop 2.795 0.499 0.499 0.499 0.499 0.5589 0.5589 0.5589 0.5589 0.5589 0.7 0.7 0.7
54 Tack Front Pkt & crotch 1 0.38 0.38 0.38 0.38 0.38 0.38 0.388 0.388 0.388 0.388 0.388 0.388
55 Sew Eyelet Hole 1.165 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12
56 Body Turning 0.8 0.14 0.14 0.14 0.14 0.14 0.14 0.16 0.16 0.16 0.16 0.16 0.16
Total   23.726 23.726 23.777 23.814 24.062 24.22 24.338 24.403 24.639 24.884 24.999 25.029

Operation Breakdown and SMV of Cargo Short Pant without Bone Pocket Excel

Written by

A.M. Amirul Islam (Washim)

Email: [email protected]

Linkedin: A.M. Amirul Islam