Operation breakdown, SMV and layout of Shirt Manufacturing

The shirt is one of the commonly worn dress all over the world. For a target level of garments manufacturing, you need to identify the operation breakdown, manpower requirement, and machine requirement. So that you can do proper production planning. Here in this article, we will share Operation breakdown, SMV and layout of Shirt Manufacturing where Total SMV is 33.84, manpower requirement is 100 and the total machine required 81 unit.

Operation breakdown, SMV and layout of Shirt Manufacturing

• Working Hour: 1
• Efficiency: 28
• Pitch Time: .31
• Target: 55

Seq. No	Body Part	Operation	Resource	SMV	Target (100%)	Cycle Time(s)	Layout MP
1	Placket	Fusing attach at front placket	Assistant Operator	0.42	143	25.20	1
2	Placket	Front placket mark n press	Sewing Iron	0.75	80	45.00	2
3	Placket	Placket make upper	SNL Auto	0.54	111	32.40	2
4	Placket	Placket make Lower	SNL Auto	0.54	111	32.40	2
5	Placket	Upper placket 1/4 top- stitch	SNL Auto	0.48	125	28.80	2
6	Placket	Deco. Placket press	Sewing Iron	0.38	158	22.80	1
7	Assembly	Front n back part match	Assistant Operator	0.28	214	16.80	1
8	Assembly	Shoulder join with/ without tape	4T OL Auto	0.30	200	18.00	1
9	Assembly	Shoulder topstitch	1NDL FL	0.28	214	16.80	1
10	Collar	Fusing attach at collar/collar stand	Sewing Iron	0.42	143	25.20	2
11	Collar	Collar mark	Assistant Operator	0.20	300	12.00	1
12	Collar	Collar make	SNL-VT	0.83	72	49.80	3
13	Collar	Corner cut n turn collar	Assistant Operator	0.30	200	18.00	1
14	Collar	Collar 1/4 topstitch	SNL Auto	0.58	103	34.80	2
15	Collar	Collar edge close n cut	SNL-VT	0.28	214	16.80	1
16	Collar	Collar band rolling	SNL Auto	0.38	158	22.80	1
17	Collar	Mark n arrange match collar with band	Assistant Operator	0.35	171	21.00	1
18	Collar	Collar attach with collar band sandwich stitch	SNL-VT	1.08	56	64.80	3
19	Collar	Collar band turn n press with necessary scissoring	Sewing Iron	0.35	171	21.00	1
20	Collar	Collar n neck mark	SNL Auto	0.32	188	19.20	1
21	Collar	Attach collar to body	SNL Auto	0.65	92	39.00	2
22	Collar	Collar close	SNL Auto	0.75	80	45.00	2
23	Collar	Collar band topstitch	SNL Auto	0.56	107	33.60	2
24	Sleeve	Sleeve side seam	4T OL Auto	0.55	109	33.00	2
25	Sleeve	Sleeve side seam topstitch	2T FL Auto	0.62	97	37.20	2
26	Assembly	Side seam join	4T OL Auto	0.55	109	33.00	2
27	Label	Care Label make	SNL Auto	0.24	250	14.40	1
28	Label	Care label tack at side	SNL Auto	0.26	231	15.60	1
29	Sleeve	Sleeve & Body sticker match & Sleeve tack	SNL Auto	0.56	107	33.60	2
30	Sleeve	Sleeve attach round	4T OL Auto	1.00	60	60.00	3
31	Back Part	Bottom hem edge rolling	SNL Auto	0.75	80	45.00	2
32	Placket	Sleeve mark for placket	Assistant Operator	0.44	136	26.40	2
33	Sleeve	Sleeve cut for placket	Assistant Operator	0.40	150	24.00	1
34	Sleeve	Sleeve lower placket binding n trims	Flat Bed	0.41	146	24.60	2
35	Placket	Secure placket base	SNL Auto	0.30	200	18.00	1
36	Placket	Sleeve upper placket fusing attach n half fold	Sewing Iron	0.42	143	25.20	2
37	Placket	Upper placket attach n 1/16 topstitch	SNL Auto	1.00	60	60.00	3
38	Placket	Sleeve upper placket close	SNL Auto	0.80	75	48.00	3
39	Placket	Upper placket 1/16 topstitch	SNL Auto	0.56	107	33.60	2
40	Placket	Sleeve placket fishtail secure	SNL Auto	0.72	83	43.20	2
41	Placket	Sleeve placket box make	SNL Auto	1.08	56	64.80	3
42	Placket	Pleat make with mark at sleeve opening	SNL Auto	0.64	94	38.40	2
43	Cuff	Fusing attach at cuff	Assistant Operator	0.28	214	16.80	1
44	Cuff	Cuff rolling	SNL Auto	0.45	133	27.00	2
45	Cuff	Cuff mark n make	SNL Auto	0.95	63	57.00	3
46	Cuff	Cuff turn n press with necessary scissoring	Sewing Iron	0.40	150	24.00	1
47	Cuff	Cuff mark n match arrange with body	Assistant Operator	0.40	150	24.00	1
48	Assembly	Cuff attach at sleeve opening	SNL Auto	0.83	72	49.80	3
49	Cuff	Cuff close	SNL Auto	0.96	63	57.60	3
50	Cuff	Cuff top-stitch	SNL Auto	0.75	80	45.00	2
51	Assembly	Sticker remove and GMTs turn	Assistant Operator	0.26	231	15.60	1
52	Assembly	Button hole position mark	Assistant Operator	0.78	77	46.80	2
53	Placket	Button hole make at Sleeve placket X4	BH Auto	0.54	111	32.40	2
54	Placket	Button hole make at front placket X9	BH Auto	1.26	48	75.60	3
55	Assembly	Button position mark	Assistant Operator	0.98	61	58.80	3
56	Placket	Button attach at placket X9 + Spare X1	BA Auto	1.20	50	72.00	3
57	Sleeve	Button attach at sleeve placket X4	BH Auto	0.48	125	28.80	2
58	Assembly	Button close	Assistant Operator	0.55	109	33.00	2
59	Assembly	Thread trims	Assistant Operator	0.45	133	27.00	2
–	–	–	Total	33.84	–	–	110

SMV Summary of Shirt Manufacturing

Sewing Helper	8.81
Sewing Machine	25.03
Sewing QI	0.00
Finishing I/M	0.00
Finishing QI	0.00
Poly Helper	0.00
Packing	0.00
Hand Tag	0.00
Total	33.84

Man Power Summary of Shirt Manufacturing

Sewing Helper	29
Sewing Machine	81
Sewing QI	0
Finishing I/M	0.00
Finishing QI	0
Poly Helper	0
Packing	0
Hand Tag	0
Total	110

Machine Summary of Shirt Manufacturing

SNL Auto	51
4T OL Auto	8
1NDL FL	1
SNL-VT	7
2T FL Auto	2
Flat Bed	2
BH Auto	7
BA Auto	3
Total	81

Written By
Sharmin Akther Diba
Industrial & Production Engineer
Rajshahi University of Engineering & Technology
Email: [email protected]
LinkedIn: Sharmin Akther Diba