Operation Breakdown and SMV of Cargo Short Pant with Bone Pocket

Operation Breakdown and SMV of Cargo Short Pant with Bone Pocket

Bone pocket making is the most critical operation for a pant, normally it makes manually by lockstitch machine but nowadays an automatic machine is used. This operation breakdown for their factory who APW machine in their facilities. Two bone pocket set in the backside of pant and cargo pocket in side-seam position. A good practice is to follow size wise SMV for garments because the size-wise operation can be bigger or smaller. Here in this article, I will share different sizewise Operation Breakdown and SMV of Cargo Short Pant with Bone Pocket.

Operation Breakdown and SMV of Cargo Short Pant with Bone Pocket

Operation Breakdown and SMV of Cargo Short Pant with Bone Pocket
Serial Operation Description Aux Size wise SMV
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 0.8 0.152 0.152 0.152 0.152 0.152 0.152 0.152 0.152 0.152 0.152 0.152
2 Atach2 vlcro to c PKT Flp 1 0.42 0.42 0.42 0.4375 0.4375 0.4375 0.46 0.46 0.46 0.46 0.46
3 Crease Cargo Pkt Flap 1 0.92 0.92 0.92 0.92 0.92 0.92 0.94 0.94 0.94 0.94 0.94
4 Form & Top sts  Cargo Flp 1.2 0.92 0.92 0.92 0.92 0.93 0.93 0.93 0.95 0.95 0.95 0.95
5 Set lbl to C.flap 1 0.22 0.22 0.22 0.22 0.24 0.24 0.24 0.26 0.26 0.26 0.26
6 Hem chess pkt 1 0.23 0.23 0.23 0.23 0.23 0.23 0.23 0.23 0.23 0.23 0.23
7 Input Fly and Zipper 0.8 0.1025 0.1025 0.1025 0.1025 0.1025 0.1025 0.1025 0.1025 0.1025 0.1025 0.1025
8 Serge Left Fly 1.2 0.1 0.1 0.1 0.1 0.12 0.12 0.12 0.15 0.15 0.15 0.15
9 Attach Zipper to Left Fly 1.2 0.24 0.24 0.24 0.24 0.25 0.25 0.25 0.26 0.26 0.26 0.26
10 1N Hem Rt Fly 1 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.14 0.14 0.14 0.14
11 Fold & atach r/fly with l/fly 1 0.28 0.28 0.28 0.3 0.3 0.3 0.3 0.3 0.32 0.32 0.33
12 Set bone facing to bk w pkt 1.4 0.28 0.28 0.28 0.28 0.28 0.28 0.28 0.28 0.28 0.28 0.28
13 Set Facing to Wht Pkt 1.5 0.65 0.65 0.65 0.65 0.65 0.65 0.65 0.65 0.65 0.65 0.65
14 Close Wht Pkt 1.4 0.27 0.27 0.27 0.27 0.27 0.27 0.275 0.275 0.275 0.275 0.275
15 Tack Wht Pkt 1 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2
16 Run & Ts 1/4 cargo pkt 0.9 1.27 1.27 1.27 1.27 1.28 1.28 1.28 1.29 1.29 1.29 1.29
17 1N Hem cargo pkt 0.8 0.55 0.55 0.55 0.55 0.55 0.55 0.56 0.56 0.56 0.56 0.56
18 Atach velco to Cargo Pkt 0.8 0.44 0.44 0.44 0.44 0.44 0.44 0.44 0.44 0.44 0.44 0.44
19 Crease cargo pkt 1 0.586 0.586 0.586 0.586 0.6 0.6 0.6 0.62 0.62 0.62 0.62
20 1N Set front pkt 1.8 0.58 0.58 0.58 0.58 0.58 0.6 0.6 0.62 0.62 0.62 0.62
21 Set Front Pkt 1 0.68 0.68 0.68 0.68 0.68 0.7 0.7 0.7 0.72 0.72 0.72
22 Set Lf Fly 1 0.23 0.23 0.23 0.23 0.25 0.25 0.25 0.28 0.28 0.28 0.3
23 J-Stitch Fly 0.89 0.32 0.32 0.32 0.32 0.34 0.34 0.34 0.37 0.37 0.38 0.38
24 Set Rt Fly and Join Crotch 1.3 0.54 0.54 0.54 0.56 0.56 0.57 0.57 0.585 0.585 0.6 0.6
25 1N Tack Front Pkt 1 0.66 0.66 0.66 0.66 0.68 0.68 0.7 0.7 0.7 0.72 0.72
26 Tack fly & label 0.85 0.254 0.254 0.254 0.254 0.254 0.254 0.254 0.254 0.254 0.254 0.254
27 1N Tack care label 1 0.33 0.33 0.33 0.33 0.33 0.33 0.33 0.33 0.35 0.35 0.35
28 2N TS  front plate 1.4 0.51 0.51 0.51 0.51 0.518 0.518 0.518 0.52 0.52 0.52 0.52
29 Cut thread FP 0.75 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2
30 Input Fnt,Bk part & Wht pkt 1 0.15 0.15 0.15 0.15 0.15 0.15 0.15 0.15 0.15 0.15 0.15
31 Pleat to back panel 0.8 0.6 0.6 0.6 0.6 0.6 0.6 0.62 0.62 0.62 0.63 0.63
32 1N middle TS side pkt 0.8 0.64 0.64 0.64 0.66 0.66 0.66 0.68 0.68 0.68 0.7 0.7
33 2N bone pocket make 1 0.6 0.6 0.6 0.6 0.6 0.6 0.63 0.63 0.63 0.63 0.63
34 Fullfell Seatseam 1.4 0.36 0.36 0.36 0.36 0.38 0.38 0.38 0.4 0.4 0.42 0.42
35 Set upr bon facing bk pkt 0.8 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3
36 Close bk wht pkt 1.4 0.57 0.57 0.57 0.57 0.59 0.59 0.59 0.61 0.61 0.61 0.63
37 Lower bone top sts 1 0.8 0.8 0.8 0.82 0.82 0.82 0.84 0.84 0.85 0.85 0.87
38 Upper bone top sts 1 0.68 0.68 0.68 0.68 0.7 0.7 0.7 0.74 0.74 0.76 0.76
39 2N TS back panel 1 0.6 0.6 0.6 0.6 0.62 0.62 0.62 0.62 0.64 0.64 0.64
40 Tack bk wht pkt 1 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.32 0.32 0.32 0.32
41 Tack Hip Pkt 1 0.26 0.26 0.26 0.26 0.26 0.26 0.26 0.28 0.28 0.28 0.28
42 Insert care label 0.6 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2
43 Safety Stitch Outseam 1 0.68 0.68 0.68 0.68 0.7 0.7 0.7 0.72 0.72 0.74 0.74
44 TopStitch Outseam 1.2 0.54 0.54 0.54 0.54 0.56 0.56 0.56 0.58 0.58 0.6 0.6
45 Input Cargo pkt,Flap,Wst Bnd 0.8 0.2 0.2 0.2 0.2 0.2 0.22 0.22 0.22 0.22 0.24 0.24
46 2N top sts cell pkt 1 0.3 0.3 0.3 0.3 0.3 0.32 0.32 0.32 0.34 0.34 0.34
47 tack cell welt pkt 1 0.55 0.55 0.55 0.55 0.57 0.57 0.57 0.59 0.59 0.6 0.6
48 Mark Cargo Pkt 0.8 0.28 0.28 0.28 0.28 0.28 0.28 0.3 0.3 0.3 0.3 0.3
49 Set Crgo Pkt Flp & mbl pkt 1.9 1 1 1 1.02 1.02 1.02 1.04 1.04 1.04 1.06 1.06
50 1N set cell pocket 1.3 0.6995 0.6995 0.6995 0.6995 0.715 0.715 0.715 0.735 0.735 0.75 0.75
51 2N Set Cargo pkt 1.8 1.72 1.72 1.72 1.75 1.75 1.75 1.75 1.8 1.8 1.85 1.85
52 Tack Cargo,Mbl Pkt & Flap 1.1 0.62 0.62 0.62 0.62 0.64 0.64 0.64 0.64 0.64 0.64 0.64
53  waist bnd join to body 1.02 0.88 0.88 0.88 0.88 0.9 0.9 0.9 0.92 0.92 0.94 0.94
54 Stay sts waist band 1 0.66 0.66 0.66 0.66 0.68 0.68 0.68 0.7 0.7 0.7 0.72
55 1/4 Round stay sts waistband 1 0.77 0.77 0.77 0.77 0.77 0.79 0.79 0.79 0.81 0.81 0.81
56 Cut thread WB 0.8 0.245 0.245 0.245 0.245 0.245 0.245 0.245 0.245 0.245 0.245 0.245
57 TS waistband 1 0.69 0.69 0.69 0.72 0.72 0.72 0.72 0.74 0.74 0.77 0.77
58 Finish Band End 1 0.62 0.62 0.62 0.62 0.62 0.64 0.64 0.64 0.64 0.64 0.64
59 Safety Stitch Inseam 1.4 0.48 0.48 0.48 0.5 0.5 0.5 0.52 0.52 0.52 0.55 0.55
60 Body Turning 0.8 0.175 0.175 0.175 0.175 0.175 0.175 0.175 0.2 0.2 0.2 0.2
61 2 N Hem Bottom 1 0.78 0.78 0.78 0.78 0.8 0.8 0.8 0.82 0.82 0.84 0.84
62 Make Loop 0.85 0.1 0.1 0.1 0.13 0.13 0.13 0.13 0.13 0.15 0.15 0.15
63 Waist tack band end 0.89 0.25 0.25 0.25 0.25 0.27 0.27 0.27 0.29 0.29 0.31 0.31
64 Tack loop 1.8 0.57 0.57 0.57 0.64 0.64 0.64 0.64 0.64 0.75 0.75 0.75
65 Tack Front Pkt & crotch 1 0.38 0.38 0.38 0.38 0.38 0.4 0.4 0.4 0.4 0.4 0.4
66 Sew Eyelet Hole 1 0.12 0.12 0.12 0.12 0.12 0.12 0.14 0.14 0.14 0.14 0.14
Total SMV 31.624 31.624 31.624 31.9215 32.329 32.479 32.7265 33.3285 33.5885 33.9785 34.0685

Operation Breakdown and SMV of Cargo Short Pant with Bone Pocket excel

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

Linkedin: A.M. Amirul Islam

Operation Breakdown and SMV of Trouser

Operation Breakdown and SMV of Trouser

Very commonly manufacturing product is trouser in knit garments, generally made by fleece fabric or single jersey, popular clothing in this generation.  Trouser sewing total SMV is 8.13 in knit garments. Here in this article, I am going to share Operation Breakdown and SMV of Trouser with all necessary data.

Operation Breakdown and SMV of Trouser
NO OPERATION M/C S.M.V TGT MAN REQ MAN ALCT Plan Work Station 
1 Front Rise Take with stripe match SNL 0.3 200 0.81 1 1
2 Front Rise Join 5OL 0.32 188 0.87 0.5 1
3 Back Rise Join 5OL 0.32 188 0.87 1 1
4 Front Rise Ts& Fly Shape Stitching W/Deco SNL 0.45 133 1.22 1 1
5 Care Label Attach SNL 0.15 400 0.41 0.5 1
6 Front & back Sticker Match MNL 0.25 240 0.68 1 1
7 Side Seam Join (Long) 5OL 0.7 86 1.89 2 2
8 Inseam Join (Long) 5OL 0.5 120 1.35 1.5 1
9 Elastic Open & Give Steam MNL 0.15 400 0.41 0.5 1
10 Elastic Measure & Cut MNL 0.12 500 0.32 0.5
11 Elastic Ring Make &Tk SNL 0.2 300 0.54 0.5 1
13 Elastic Mark For Attach MNL 0.2 300 0.54 0.5
12 Mark Hole Position & Sew BH 0.25 240 0.68 1 1
14 Waist Belt Join 4OL 0.5 120 1.35 1 1
15 Elastic Fold &Tk SNL 0.4 150 1.08 1 1
16 Waist Belt Ts KS 0.6 100 1.62 1 1
17 Drawstring Measure & Cut MNL 0.12 500 0.32 0.5 1
18 Insert Drawstring & Middling MNL 0.6 100 1.62 2 2
19 Drawstring Btk BT 0.35 171 0.95 0.5 1
20 Drawstring Mid Btk & Cross Btk BT 0.35 171 0.95 1 1
21 Bottom Hem DNL 0.6 100 1.62 2 2
22 Thread Trimming W/Waist Tk Remove MNL 0.7 86 1.89 1.5 1
Total 8.13   22 22 23

Operation Breakdown and SMV of Trouser

You may also love to read: Fabric Consumption of a Trouser

Summary of Trouser SMV and Operation Bulletin

Summary of Trouser SMV and Operation Bulletin
Inline S.M.V
SEWING 5.99
MANUAL 2.14
IRON 0
TOTAL 8.13
Man level 22
Tact time 0.37
100% Tgt/h 162
75% Tgt/h 122
65% Tgt/h 106
Machine Type Requisition
5OL 5
4OL 1
SNL 4
DNL 2
KS 1
BT 2
FL 0
BH 1
Total 15.5
Manpower Requisition
Operator 15.5
Iron Man
MANUAL 6
Total 21.5

Summary of Trouser SMV and operation bulletin

Operation Breakdown and SMV of Trouser excel

Written by

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

Linkedin: A.M. Amirul Islam

Roles of Industrial Engineering in Garments Factory

Roles of Industrial Engineering in Garments Factory

Industrial engineering (IE) plays a vital role in the apparel industry, that’s why Industrial engineering job roles are very important for garments factory. When we need to reduce cost and improve work efficiency in this competitive era, the apparel industry hires an Industrial Engineer to do that job smartly. Apparel manufacturing industry is growing quickly by applying IE in their facility. I this article I am giving a list of IE activities in garments factory which will help you to understand the Roles of Industrial Engineering in Garments Factory.

Roles of Industrial Engineering in Garments Factory

Objectives of Industrial Engineering (IE) in the Apparel Industry

  1. To increase productivity
  2. Process improvement by motion reducing.
  3. Reduce work in process (WIP) and remove the bottleneck.
  4. Increase efficiency of operations
  5. Reduce man machine ratio
  6. Process improvement to reduce cost, waste and rejection Reduce wastage and defects
  7. Fill up Key Performance Indicator (KPI) target.
  8. Keep workplace and environment safe
  9. Production planning and implementation
  10. Evaluate operator and staff performance, disciplinary matters, training needs, and their career development.
  11. Set the target and make a draft, layout design of the machine requirement, material flow, and workstation to bring the best possible efficiency. Modern tools are used to design of the layout.
  12. Monitor factory performance in terms of quality, delivery, cost-efficiency and target improvements with the internal factory team and taking necessary corrective action.
  13. Manpower balancing, target setting, and monitoring achievements.

Daily Activities and Duties of an Industrial Engineer in the Apparel Industry

  1. Collect line loading plan from the Planning Department
  2. Attend in Pre-Production (PP) meeting
  3. Collect size set sample and make operation bulletin accordingly.
  4. Collect Operation Bulletin and make a paper layout
  5. Discuss with Maintenance in-charge regarding machine, folder, attachment and Technical personnel for technical issues.
  6. Make discussion with a floor in-charge about layout according to paper layout
  7. Check Daily Non-productive time (NPT) and reduce machine breakdown time.
  8. Make layout according to paper layout
  9. Make line balancing according to target and capacity study during 2 – 3 days of layout
  10. Find out the bottleneck process and solve it
  11. If needed make 1-hour production study in required process
  12. Everyday input and output monitoring
  13. Give daily production target and follow up production achievement.
  14. Hourly production follow-up
  15. Everyday 5S related activities monitoring
  16. Cross check thread consumption for every new style.
  17. Ensure up to 65%-70% efficiency.
  18. Workstation design
  19. Operators motion development by correcting faulty motion.
  20. Reduce worker absenteeism and turnover rate
  21. 5 pcs flow by reducing WIP
  22. Reduce line setting time or throughput time.
  23. Proper utilization of manpower by reducing unnecessary helping process.
  24. Establish a meeting in-between QC and operators regarding critical points of the style while layout.
  25. Prepare daily Man/ Machine report
  26. Developing cut to ship ratio.
  27. Work to reduce absenteeism and operator turnover

Roles of Industrial Engineering in Garments Factory pdf

Written by

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

Linkedin: A.M. Amirul Islam

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 Responsibility of IE in Apparel Industry

Before appointing an industrial engineer for the apparel industry, you have to keep in mind the Job Responsibility of IE in Apparel Industry. Here IE means Industrial Engineering. The world has limited resources but day by day we need to produce more and more product. The challenge is to increase productivity by using the least amount of resources. The garments industry is very much competitive. So in this competitive industry, it is a big challenge for Bangladesh or any other country to survive. We are looking for a solution where we will get more productive technology at a lower cost. Industrial Engineering is all about optimization of limited resources. Generally, Optimization, Planning, and Process Control is the core work in apparel for the industrial engineering department.

Job Responsibility of IE in Apparel Industry

Nowadays IE playing the key role in the apparel industry. Industrial Engineering Job is not an easy job, always engineers need to take on the challenge and bring a complete solution. The person who is responsible for industrial engineering is considered as an industrial engineer. I made a list of industrial engineering activities in the apparel industry.

Job Responsibility of IE in Apparel Industry

Major Work of Industrial Engineering in Garments

Industrial Engineering deals with the following activities:

  1. Time Study, Motion study
  2. Taking the capacity study of full-line and line balancing for clean-up bottleneck area.
  3. Methods developments & analysis as a side of quality & quantity.
  4. Follow-up the low performing Operators.
  5. Operation breakdown, Operation Bulleting / Layout
  6. SMV calculation by time study.
  7. Operator skill Summery.
  8. Train up production staff on efficiency.
  9. Process-wise operator skill development.
  10. Nonproductive time (Loss Time) record and reduce.
  11. Hourly Production Monitoring & Achieve the line Target.
  12. Prepare Man machine report.
  13. 5s implementation, Training, and Auditing
  14. Work on 7 QC tools to minimize defect.
  15. Statistical analysis for continuous quality improvement.
  16. Production Planning and control, Planning Calculations
  17. Capacity Study
  18. Production Study
  19. PDCA Cycle
  20. 7 Wastage reduce
  21. Manpower Budget Planning
  22. CPM, CM Calculation
  23. Line Cost Calculation, Floor capacity calculation
  24. SPM, EPM, PCL Calculation
  25. Reduce WIP (Work in Process)
  26. Operator, Line and floor efficiency Calculation
  27. Follow up KPI (Key Performance Indicator) and Report
  28. Inventory Control in all section
  29. Implementation of lean manufacturing tools and Six Sigma
  30. Provide Incentive for operator and Production staffs
  31. Manpower requisition and set up
  32. Eliminating excess manpower
  33. Improving Productivity through a detailed analysis of the process by process
  34. Smooth supply chain management from raw material to output
  35. Helping to launch the TQM (Total Quality Management) system in a factory
  36. Implement traffic light system on the floor & reduced sewing defect percentage
  37. Co-ordination with merchandising
  38. Fabric & thread consumption.
  39. Garments analysis & style development for reducing costing.

Please mention in the comment box if I missed any point.

Written by

A.M. Amirul Islam (Washim)

Facebook: Amirul Islam Washim
E-mail: [email protected]

7 QC Tools in Apparel Industry

7 QC (Quality Control) tools are very effective for apparel or any other types of the factory to solve almost every type of problem in a factory operation. These are the tools of troubleshooting quality issues, based on numeric value. 7 QC tools in apparel industry is a set of data analysis tools used to support continuous quality improvement efforts. If you can use these seven fundamental tools, then definitely quality control will be effective for your company.

7 QC Tools in Apparel Industry

  1. Histogram
  2. Check Sheet (Tally Sheet)
  3. Cause-and-Effect Diagram
  4. Pareto Chart
  5. Scatter Diagram
  6. Control Chart
  7. Stratification

7 QC Tools in Apparel Industry

Benefits of 7 QC Tools

  • Improve management decision making skills
  • Collect, present, Identify and analyses data
  • Implement Six Sigma
  • Control cost of poor quality
  • Reduce variations and improve quality
  • Reduce defects and improve production
  • Reduce cycle time and improve efficiency
  • Continuous quality improvement
  • Encourages teamwork and confidence
  • Enhances customer satisfaction through improved quality product

Explanation of 7 QC Tools for Apparel Industry

  1. Histogram

Histogram is also a bar chart. It is a graphical chart based on numeric value for showing frequency distribution of database. People become confused among Histograms and Bar Charts. A histogram is used for continuous data, where the bins represent ranges of data, while a bar chart is a plot of categorical variables. Some authors recommend that bar charts have gaps between the rectangles to clarify the distinction.

Histogram for Apparel Industry

Download: Histogram Template (excel 31kb)

  1. Check Sheet (Tally Sheet)

The Check Sheet/Tally sheet is a simple document that is used for collecting data in real time and at the location where the data is generated. The document is typically a blank form that is designed for the quick, easy, and efficient recording of the desired information, which can be either quantitative or qualitative. When the information is quantitative, the check sheet is sometimes called a tally sheet. A tally sheet to collect data on frequency of occurrences which custom designed by user.

Check Sheet or Tally Sheet

Download: Tally-sheet-template (excel 75kb)

  1. Cause-and-effect diagram (Ishikawa Diagram / Fishbone Diagram)

Cause-and-effect diagram is look like a fish that’s why it’s called Fishbone Diagram, also called Ishikawa diagram, herringbone diagrams or Fishikawa diagrams, a visualization tool for categorizing the potential causes of a problem in order to identify its root causes. Causal diagrams created by Kaoru Ishikawa that show the causes of a specific event. Dr. Kaoru Ishikawa developed the “Fishbone Diagram” at the University of Tokyo in 1943.To break down (in successive layers of detail) root causes that potentially contribute to a particular effect. This diagram is used in process improvement methods to identify all of the contributing root causes likely to be causing a problem.

How to Work on Fishbone

If you find a problem and want to make fishbone diagram. First need brainstorming about the defect to find out types of causes based on 6 basic things. These are:

  • Machine
  • Manpower
  • Environment
  • Method
  • Materials
  • Measurement

Brainstorm all the possible causes of the problem. Ask: “Why does this happen?” As each idea is given, the facilitator writes it as a branch from the appropriate category. Causes can be written in several places if they relate to several categories. For example you can see fishbone in the below:

Fishbone Diagram of QC Tools

Download: Cause and Effect diagram Template (excel 34kb)

4. Pareto Chart (80/20 Rule)

A Pareto chart is a bar graph. The lengths of the bars represent frequency or cost (time or money), and are arranged with longest bars on the left and the shortest to the right. In this way the chart visually depicts which situations are more significant.

The Pareto principle

The Pareto principle (also known as the 80–20 rule, the law of the vital few, and the principle of factor sparsity) states that, for many events, roughly 80% of the effects come from 20% of the causes. More generally, the Pareto Principle is the observation (not law) that most things in life are not distributed evenly. In apparel industry, you can see the data in the below that first 5 defects covered 50% of total defect. So 80-20 rules will not cover all-time 80% problem for 20% causes. It can mean all of the following things:

  • 20% of the defects number cumulate 80% of the total defects
  • 20% of the operator produce 80% of the defects
  • 20% of the customers create 80% of the revenue

Pareto for Apparel Industry

Pareto Chart of Cutting Defects

Download: Pareto Chart Template (excel 25kb)

5. Scatter Diagram

The scatter diagram graphs pairs of numerical data, with one variable on each axis, to look for a relationship between them. If the variables are correlated, the points will fall along a line or curve. The better the correlation, the tighter the points will hug the line. The scatter diagram Collect pairs of data where a relationship is suspected.

Scatter Diagram

6. Control Chart (Shewhart Chart)

Control charts, also known as Shewhart charts or process-behavior charts, are a statistical process control tool used to determine if a manufacturing or business process is in a state of control. A control chart shows how data frequency changes, defects trends and compares with previous time record. Control chart monitor process and hypothetical prediction. Apparel industry need to reduce defect frequency to get quality improvement.

Control Chart for Apparel

Download: Control Chart Template (excel 17kb)

7. Stratification (Divide and Conquer), can be alternative of flow chart or run chart

Stratification is a method of dividing data into subcategories and classify data based on a group, division, class or levels that helps in deriving meaningful information to understand an existing problem. The main purpose of Stratification is to divide the data and conquer the meaningful information to solve a problem. The visual nature of the chart makes patterns jump out.

Implementation of 7 QC Tools

To implement these tools in your industry, you must have to do Pareto, Fishbone for every section. Result publishes visibly in each line or area in board. People will be conscious to reduce defect. There improvement tracking on control chart also visible for each line/area. You have to find root cause from the root level for cause and effect diagram. Data and data collection must be accurate. Every section has to be taken corrective action based on quality data. Every section must do a quality meeting to take new decision for quality control at least once per month.

Written by

A.M. Amirul Islam (Washim)

Facebook: Amirul Islam Washim

Phone:+8801929643301
E-mail: [email protected]