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Operation Breakdown, SMV and Layout of Brooke Hoodies

By Nahian Mahmud Shaikat July 30, 2019 October 20, 2019 Apparel, Industrial Engineering (IE)

Total SMV = 15.66
Total Manpower Requried = 56
Total Number of Machine Required = 45

Operation Breakdown, SMV and Layout of Brooke Hoodies

Seq. No	Body Part	Operation	Resource	SMV	Layout MP
1	Assembly	Front n back part match	Assistant Operator	0.26	1
2	Assembly	Shoulder Join with/ without tape	4T OL Auto	0.36	1
3	Hood	Hood two part join	4T OL Auto	0.32	1
4	Hood	Hood band attach at hood opening	Flat Bed	0.35	1
5	Hood	Hood edge neaten	OL Cutter	0.26	1
6	Hood	Hood edges tack as circle	SNL Auto	0.24	1
7	Hood	Hood n body mark	Assistant Operator	0.30	1
8	Hood	Hood tack at neck	SNL Auto	0.26	1
9	Hood	Hood attach to body	4T OL Auto	0.35	1
10	Neck	Back neck binding	Flat Bed	0.30	1
11	Neck	Binding edges tack n cut	SNL Auto	0.36	1
12	Label	Label position mark	Assistant Operator	0.16	1
13	Neck	Back neck top stitch insert label	SNL Auto	0.40	1
14	Sleeve	Sleeve n body match	Assistant Operator	0.35	1
15	Sleeve	Insert Sleeves	4T OL Auto	0.56	2
16	Label	Care Label Make	SNL Auto	0.24	1
17	Assembly	Side/ sleeve seam insert care label	4T OL Auto	0.70	2
18	Cuff	Cuff join as a circleX2	SNL Auto	0.28	1
19	Cuff	Cuffs fold in half and mark	Assistant Operator	0.24	1
20	Cuff	Cuff attach at sleeve opening	4T OL Auto	0.50	2
21	Assembly	Bottom binding n trims	Flat Bed	0.50	2
22	Assembly	Front n back part match	Assistant Operator	0.26	1
23	Assembly	Side seam	4T OL Auto	0.45	2
24	Assembly	Binding at one side to another around n trim	Flat Bed	0.90	3
25	Assembly	Mark and side seam topstitch	SNL Auto	1.00	4
26	Waist Belt	Elastic press,measure & cut	Sewing Iron	0.20	1
27	Waist Belt	Waist band join as a circle n mark	SNDL Edg Cutter	0.30	1
28	Waist Belt	Elastic join as a circle & mark	DNL Lock Switch Auto	0.30	1
29	Waist Belt	Mark n make hole for eyelet	Snap	0.28	1
30	Waist Belt	Eyelet attach	Snap BA	0.35	1
31	Waist Belt	Sandwich elastic with waist band & tack	SNL Auto	0.40	1
32	Waist Belt	Waist band fold run stitch	SNL[Chain STS]	0.32	1
33	Waist Belt	Waist band lower edge close n mark	SNL[Chain STS]	0.45	2
34	Waist Belt	Attach waist band to body	4T OL Auto	0.50	2
35	Assembly	Top n bottom part match	Assistant Operator	0.28	1
36	Assembly	Top n bottom part tack	SNL Auto	0.30	1
37	Assembly	Top n Bottom attach together	4T OL Auto	0.50	2
38	Assembly	Sticker remove and GMTs turn	Assistant Operator	0.25	1
39	Cuff	Cuff top-stitch	2NDL FL	0.50	2
40	Assembly	Drawsting insert through the waist channel	Assistant Operator	0.30	1
41	Assembly	Drawsting secure at CB waist band	BT	0.18	1
42	Assembly	Thread trims	Assistant Operator	0.35	1
–	–	–	Total	15.66	56

Operation Breakdown, SMV and Layout of Brooke Hoodies

SMV Summary of Brooke Hoodies

Sewing Helper	2.95
Sewing Machine	12.71
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	15.66

Man Power Summary of Brooke Hoodies

Sewing Helper	11
Sewing Machine	45
Sewing QI	0
Finishing I/M	0.00
Finishing QI	0
Poly Helper	0
Packing	0
Hand Tag	0
Total	56

Machine Summary of Brooke Hoodies

4T OL Auto	15
Flat Bed	7
OL Cutter	1
SNL Auto	12
SNDL Edg Cutter	1
DNL Lock Switch Auto	1
Snap	1
Snap BA	1
SNL[Chain STS]	3
2NDL FL	2
BT	1
Total	45

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

No comments

Operation Breakdown, SMV and Layout of Cody Manufacturing

By Nahian Mahmud Shaikat July 30, 2019 July 30, 2019 Apparel, Industrial Engineering (IE)

Operation Breakdown SMV Layout of Cody Manufacturing

Cody basically wears under the blazer which ensures proper fit of blazer and gives a stylish look of a person. In this article we will share Operation breakdown, SMV and layout of Cody manufacturing where SMV is 28.14, the total manpower requirement is 88, and the number of machines required is 67.

Seq. No	Body Part	Operation	Resource	SMV	Target (100%)	Layout MP
1	Front Part	Upper body front two pannel match n join	4T OL Auto	0.40	150	1
2	Pocketing	Pocket position mark	Sewing Helper	0.28	214	1
3	Pocketing	Press welt with fusing paper n mark	Sewing Iron	0.32	188	1
4	Pocketing	Welt attach at pocket position mark	SNL Auto	0.52	115	1
5	Pocketing	Pocket bag attach	SNL Auto	0.52	115	1
6	Pocketing	Cut pocket mouth n form fishtail	Sewing Helper	0.64	94	2
7	Pocketing	Pocket liner attach at pocket position	SNL Auto	0.52	115	1
8	Pocketing	Welt edge secure	4T OL Auto	0.20	300	1
9	Pocketing	Secure fishtaills	SNL Auto	0.48	125	1
10	Pocketing	Pocket bag close	4T OL Auto	0.52	115	1
11	Pocketing	Pocket topstitch with corner close	SNL Auto	0.68	88	2
12	Pocketing	Topstitch pocket bags	SNL Auto	0.54	111	1
13	Pocketing	Secure pocket edges	SNL Auto	0.32	188	1
14	Back Part	Upper body centre back pannel match n join	4T OL Auto	0.25	240	1
15	Back Part	Topstitch on CB seam	SNL Auto	0.35	171	1
16	Back Part	Upper body back side two pannel match n join	4T OL Auto	0.40	150	1
17	Assembly	Front n back part match	Sewing Helper	0.25	240	1
18	Assembly	Shoulder Join with/ without tape	4T OL Auto	0.28	214	1
19	Assembly	Shoulder top-stitch	SNL Auto	0.30	200	1
20	Assembly	Side seam	4T OL Auto	0.40	150	1
21	Back Part	Back part mark for belt position	Sewing Helper	0.16	375	1
22	Back Part	Fusing attach at belt	Sewing Iron	0.16	375	1
23	Back Part	Left n right side belt mark with template	Sewing Helper	0.20	300	1
24	Back Part	Left n right side belt make leaving open end	SNL Auto	0.68	88	2
25	Back Part	Left n right side belt turn with necessary scissoring	Sewing Helper	0.30	200	1
26	Back Part	Left n right side belt topstitch	SNL Auto	0.68	88	2
27	Back Part	Belt edge o/l	4T OL Auto	0.10	600	1
28	Back Part	Belt edge secure	SNL Auto	0.16	375	1
29	Back Part	Belt mark for attach with cross tack	Sewing Helper	0.14	429	1
30	Back Part	Belt attach with cross tack	SNL Auto	0.75	80	2
31	Back Part	Secure belt join	BT	0.24	250	1
32	Front Part	Liner front two pannel match n join	SNL Auto	0.40	150	1
33	Back Part	Liner centre back pannel match n join	4T OL Auto	0.25	240	1
34	Back Part	Liner back side two pannel match n join	4T OL Auto	0.40	150	1
35	Assembly	Front n Back panel match	Sewing Helper	0.25	240	1
36	Assembly	Shoulder Join with/ without tape	4T OL Auto	0.26	231	1
37	Assembly	Liner side seam	4T OL Auto	0.36	167	1
38	Label	Care Label Make	SNL Auto	0.22	273	1
39	Label	Care label tack at side	SNL Auto	0.22	273	1
40	Facing	Fusing attach at facing	Folding	0.50	120	2
41	Facing	Armhole facing circular join	SNL Auto	0.48	125	1
42	Assembly	Facing n body mark	Sewing Helper	0.24	250	1
43	Assembly	Armhole facing tack to liner	SNL Auto	0.40	150	1
44	Assembly	Armhole facing attach to liner	4T OL Auto	0.45	133	2
45	Assembly	Facing join topstitch	SNL Auto	0.60	100	2
46	Assembly	Bottom facing edges join	SNL Auto	0.24	250	1
47	Assembly	Facing attach at bottom	4T OL Auto	0.30	200	1
48	Assembly	Facing join topstitch	SNL Auto	0.45	133	1
49	Assembly	Back neck n front facing edges join	SNL Auto	0.28	214	1
50	Assembly	Facing n body mark	Sewing Helper	0.28	214	1
51	Assembly	Facing tack to body	SNL Auto	0.40	150	1
52	Assembly	Facing attach to front n back neck	4T OL Auto	0.56	107	2
53	Assembly	Facing join topstitch	SNL Auto	0.70	86	2
54	Label	Label position mark	Sewing Helper	0.14	429	1
55	Label	Label Make	SNL Auto	0.20	300	1
56	Back Part	Label attach at back neck	SNL Auto	0.32	188	1
57	Assembly	Upper n liner part tack at underarms, bottom, shoulder neck point n front	SNL Auto	0.80	75	2
58	Assembly	Upper n liner part seam tack at the bottom	SNL Auto	0.50	120	1
59	Assembly	Upper n liner part attach leaving an open edge	4T OL Auto	1.10	55	3
60	Assembly	Bluffstitch on upper n liner part attach seam	SNL Auto	1.30	46	3
61	Assembly	Hand to turn upper n liner part	Sewing Helper	0.40	150	1
62	Assembly	Close open end	SNL Auto	0.32	188	1
63	Assembly	Sticker remove and GMTs turn	Sewing Helper	0.15	400	1
64	Assembly	Topstitch around n armhole	SNL Auto	1.40	43	3
65	Front Part	Mark n make the buttonhole	BH Auto	0.50	120	2
66	Front Part	Mark for buttons x 5	Sewing Helper	0.15	400	1
67	Front Part	Button attach x5 + 1 spare	BA Auto	0.48	125	2
68	Assembly	Thread trim n button close	Sewing Helper	0.40	150	2
–	–	Total	–	28.14	–	88

Operation Breakdown, SMV and Layout of Cody Manufacturing

SMV Summary of Cody Manufacturing

Sewing Helper	4.96
Sewing Machine	23.18
Sewing QI	0
Finishing I/M	0
Finishing QI	0
Poly Helper	0
Packing	0
Hand Tag	0
Total	28.14

Man Power Summary of Cody Manufacturing

Sewing Helper	21
Sewing Machine	67
Sewing QI	0
Finishing I/M	0.00
Finishing QI	0
Poly Helper	0
Packing	0
Hand Tag	0
Total	88

Machine Summary of Cody Manufacturing

4T OL Auto	20
SNL Auto	42
BT	1
BH Auto	2
BA Auto	2
Total	67

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

No comments

Operation Breakdown, SMV and Layout of Chino Pant Manufacturing

By Nahian Mahmud Shaikat July 29, 2019 July 29, 2019 Apparel, Industrial Engineering (IE)

Operation Breakdown, SMV and Layout of Chino Pant Manufacturing

Chino Pants is one of the commonly worn cloth preferable by both male and female as a casual dress which is made from 100% cotton. Trouser is a well-known product which is a chino pant. Here in this article, you will have a detailed idea of operation breakdown, SMV and layout of chino pant manufacturing. For chino pant total SMV is 36.86 and number of operator and helper requirement is 92.

Chino Pant

Operation Breakdown Sheet of Chino Pant

SEQ NO	OPERATION	M/C Types	M/C OPN	MNL OPN	ACT
–	–	–	SMV	SMV	OP
1	Match & join back rise	4TH/OL	0.36	–	1
2	Mark for back dart	MNL	0.24	0.24	1
3	Make back dart & top edges tack	SNLS	0.66	–	1
4	Welt pocket position mark	MNL	0.44	0.44	1
5	Fusing attach & half fold pocket welts n mark	IRON	0.40	–	1
6	Attach pocket welts & bag	SNLS	1.10	–	2
7	Cut to form pocket fishtails	MNL	0.70	0.70	1
8	Attach pocket liner	SNLS	0.55	–	1
9	Secure fishtails	SNLS	0.64	–	1
10	Neaten pocket welt	4TH/OL	0.32	–	1
11	Topstitch pocket welts	SNLS	0.52	–	1
12	Pocket bag close	4TH/OL	0.68	–	1
13	Secure pocket bag corners	SNLS	0.80	–	1
14	Pocket topstitch with corner	SNLS	0.80	–	2
15	Secure welt corner×4	B/T	0.40	–	1
16	Patch label position mark	MNL	0.18	0.18	1
17	Attach patch label	SNLS	0.40	–	1
18	Piping cut [Full body]	PC	0.36	–	1
19	Mark for front pleat	MNL	0.24	0.24	1
20	Make front pleat	SNLS	0.36	–	1
21	Fussing attach pocket facing & Cap edges	IRON	0.52	–	1
22	Pocket facing attach at both side & edges close	SNLS	1.50	–	2
23	Mark n Pocket liner attach to position	SNLS	0.70	–	1
24	Pocket corner snip & turn	MNL	0.40	0.40	1
25	Pocket opening 1/16 topstitch	SNLS	0.50	–	1
26	Turn n Pocket opening 1/4 topstitch with corner	SNLS	0.68	–	1
27	Pocket bag fold & close	4TH/OL	0.45	–	1
28	Secure pocket bag OL seam	SNLS	0.24	–	1
29	Pocket bag close to side	SNLS	0.45	–	1
30	Pocket bag staystitch to waist	SNCS	0.30	–	1
31	Fusing attach at fly & fly box	IRON	0.24	–	1
32	Fly box serging	3TH O/L	0.20	–	1
33	Make double fly	SNLS	0.40	–	1
34	Fly turn & press	IRON	0.26	–	1
35	Fron pannel rise serging	4TH/OL	0.25	–	1
36	Attach Single fly to front	SNLS	0.33	–	1
37	Bluffstitch Single fly join	SNLS	0.30	–	1
38	Zipper puller secure tack	SNLS	0.16	–	1
39	Attach zipper to single fly with zipper mark	SNLS	0.36	–	1
40	Zipper join topstitch	SNLS	0.30	–	1
41	Front pannel match	MNL	0.26	0.26	1
42	Zipper attach to front with mark	SNLS	0.36	–	1
43	Zipper attach topstitch	SNLS	0.32	–	1
44	Double fly attach to front	SNLS	0.35	–	1
45	Front crotch attach	SNLS	0.26	–	1
46	Front rise join	4TH/OL	0.26	–	1
47	Piping attach at single fly & cut	1FL/BIN	0.25	–	1
48	Fly secure at waist & piping secure at crotch	SNLS	0.36	–	1
49	Sew ‘J’ stitch by mark/pattern	SNLS	0.35	–	1
50	Fly secure mark n tack	SNLS	0.24	–	1
51	Front n back part match & side mark	MNL	0.56	0.56	1
52	Piping make & cut	SNLS	0.36	–	1
53	Piping attach at front & back side together	SNLS	0.85	–	2
54	Side seam join	4TH/OL	0.70	–	1
55	Inseam join	4TH/OL	0.70	–	1
56	Crotch point secure	B/T	0.16	–	1
57	Fusing attach at waist band	IRON	0.34	–	1
58	Innerside WB piping attach & cut	1FL/BIN	0.40	–	1
59	Waistband fold & press	IRON	0.35	–	1
60	Fusing attach at waist loop with folder	IRON	0.25	–	1
61	Loop make & turn	1FL/BIN	0.40	–	1
62	Loop press & cut to length	IRON	0.40	–	1
63	Loop position mark at waist & arrange	MNL	0.45	0.45	1
64	Loop tack to body (5X2)	SNLS	1.00	–	2
65	Waist belt edge tack to body	SNLS	0.30	–	1
66	Waist band attach	SNLS	0.75	–	2
67	Waist band mouth mark & excess cut	MNL	0.32	0.32	1
68	Waist band mouth close & turn	SNLS	0.65	–	1
69	Label position mark	MNL	0.16	0.16	1
70	Label make	SNLS	0.16	–	1
71	Label attach at waist	SNLS	0.40	–	1
72	WB bind edge tack to inside & close edge	SNLS	0.40	–	1
73	Waist band close	SNLS	0.75	–	2
74	Sticker remove & gmts turn	MNL	0.26	0.26	1
75	Waist band mark & button attach X1 +1 spare	B/A	0.30	–	1
76	Mark n form button hole X1	B/H	0.20	–	1
77	Mark for loop high-low position	MNL	0.40	0.40	1
78	Loop top edge tack to WB X5	SNLS	0.60	–	1
79	Secure loop top & bottom	B/T	1.00	–	2
80	Pocket opening secure	B/T	0.40	–	1
81	J stitch secure	B/T	0.16	–	1
82	Legs hem	2FL/ CY	0.53	–	1
83	Final thred trimming & button & ZIP close	MNL	0.50	0.50	2
–	Total	–	36.86	5.11	92

Number of Operator and Helper Requirement

Code	Machine name	Quantity
SNLS	Single Needle Lock Stitch	46
SNCS	Single Needle Chain Stitch	1
3TH O/L	3 Thread Over Lock	1
4TH/OL	4 Thread Over Lock	8
2FL/ CY	2 Needle Flat lock Cylinder Bed	1
1FL/BIN	1 Needle Flat lock Binding Machine	3
B/A	Button Attach	1
B/H	Button Hole	1
B/T	Bar Tack	6
IRON	Iron With Table	8
MNL	Manual (Helper)	15
PC	Piping Cut	1
–	Total Operator and Helper	92

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

No comments

Operation Breakdown, SMV and Layout of Blazer Manufacturing

By Nahian Mahmud Shaikat July 28, 2019 July 29, 2019 Apparel, Industrial Engineering (IE)

A blazer is a type of jacked which is preferable by both male and female as a formal dress. Here in this article, you will have an idea of operation breakdown, SMV and layout of blazer manufacturing. As a garments (blazer) manufacturer you must know this. The total SMV is 21.85, Manpower requirement is 79 and the number of machines is 55.

Operation Breakdown, SMV and Layout of Blazer Manufacturing

Working Hour: 1
Efficiency: 30
Pitch Time: .28
Target: 65

Seq. No	Body Part	Operation	Resource	SMV	Target (100%)	Layout MP
1	Pocketing	Pocket position mark	Assistant Operator	0.48	125	2
2	Pocketing	Fusing attach at pocket edge	Sewing Iron	0.20	300	1
3	Pocketing	Pocket edge neaten	3T OL Auto	0.32	188	1
4	Pocketing	Pocket hem	1NDL FL	0.38	158	1
5	Pocketing	Pre Iron pocket edges	Sewing Iron	0.80	75	3
6	Pocketing	Pocket attach X2	SNL Auto	1.50	40	4
7	Pocketing	Pocket extra rawedge cut	Assistant Operator	0.60	100	2
8	Assembly	Front n back part match	Assistant Operator	0.28	214	1
9	Assembly	Shoulder Join with/ without tape	4T OL Auto	0.30	200	1
10	Sleeve	Sleeve pannel attach	4T OL Auto	0.52	115	2
11	Sleeve	Sleeve n Body match	Assistant Operator	0.35	171	1
12	Sleeve	Insert Sleeves	4T OL Auto	0.56	107	2
13	Sleeve	Fusing attach at sleeves opening	Sewing Iron	0.20	300	1
14	Sleeve	Sleeve edge neaten	3T OL Auto	0.36	167	1
15	Sleeve	Sleeve hems- Flat	1NDL FL	0.40	150	2
16	Sleeve	Sleeve hems Inner tack	SNL Auto	0.36	167	1
17	Label	Care Label Make	SNL Auto	0.24	250	1
18	Assembly	Side/sleeve seams ins care label- LS	4T OL Auto	0.80	75	3
19	Assembly	Fusing attach at bottom n front opening,neckline	Sewing Iron	0.60	100	2
20	Assembly	Bottom edge neaten	3T OL Auto	0.40	150	2
21	Assembly	Bottom hem	1NDL FL	0.45	133	2
22	Collar	Fusing attach at collar/collar stand	Sewing Iron	0.20	300	1
23	Collar	Collar make	4T OL Auto	0.35	171	1
24	Collar	Bluffstitch collar	SNL Auto	0.35	171	1
25	Facing	Fusing attach at facing	Fusing M/C	0.28	214	1
26	Facing	Facing edge neaten	5T OL	0.45	133	2
27	Facing	Facing edge secure	4T OL Auto	0.20	300	1
28	Facing	Facing attach at front part	4T OL Auto	0.60	100	2
29	Assembly	Facing n body mark	Assistant Operator	0.32	188	1
30	Facing	Bluffstitch facing join seam	SNL Auto	1.20	50	4
31	Assembly	Facing tack to body	SNL Auto	0.30	200	1
32	Collar	Collar mark	Assistant Operator	0.20	300	1
33	Collar	Collar stand edge close/ rolling stitch	SNL Auto	0.32	188	1
34	Assembly	Body mark	Assistant Operator	0.22	273	1
35	Collar	Collar tack at neck	SNL Auto	0.28	214	1
36	Collar	Collar attach at neck	SNL Auto	0.45	133	2
–	–	–	Total	21.85	–	79

Operation Breakdown, SMV and Layout of Blazer Manufacturing

SMV Summary of Blazer Manufacturing

Sewing Helper	6.08
Sewing Machine	15.77
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	21.85

Man Power Summary of Blazer Manufacturing

Sewing Helper	24
Sewing Machine	55
Sewing QI	0
Finishing I/M	0.00
Finishing QI	0
Poly Helper	0
Packing	0
Hand Tag	0
Total	79

Machine Summary of Blazer Manufacturing

3T OL Auto	4
1NDL FL	5
SNL Auto	27
4T OL Auto	13
Fusing M/C	1
5T OL	2
BH Auto	2
BA Auto	1
Total	55

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

No comments

Operation breakdown, SMV and layout of Shirt Manufacturing

By Nahian Mahmud Shaikat July 28, 2019 July 28, 2019 Apparel, Industrial Engineering (IE)

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.

Measurement Sheet of Shirt Manufacturing

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

Operation breakdown, SMV and layout of Shirt Manufacturing

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

One Comment

CM Analysis and Feedback of Garments

By Nahian Mahmud Shaikat July 15, 2019 September 5, 2019 Apparel, Industrial Engineering (IE)

CM Analysis and Feedback of Garments

This analysis is done in a famous knit factory of Bangladesh based on SMV, CM, and efficiency. SMV -efficiency variance, CM earning and loss report also included in this analysis. Hope this article would help you.

Dec’18 to Feb ’19 all unit DPR summary

Total Sewing quantity: 14.28 M PCs
Average MKT SMV/PCs: 8.93
Average Sew SMV/PCs: 8.72
Average Layout MP(OP+HLP): 36
Average Used MP(OP+HLP): 38
Average Expected Efficiency: 44.93%
Average Achieved Efficiency: 42.54%
Average MKT CM/DZn: $8.60
Average PLAN TGT CM/DZn: $11.72
Average SEW CM/DZn (USED) : $13.52
MKT Vs Plan Tgt CM Variance: $3933.0123 M
MKT Vs Used CM Variance: $6192.5275 M
Plan Tgt Vs Used CM Variance: $2259.5151 M

Dec’18 to Feb’19 unit-01 DPR summary

Total Sewing quantity: 5.49 M PCs
Average MKT SMV: 8.44
Average Sew SMV: 8.26
Average Layout MP(OP+HLP): 34
Average Used MP(OP+HLP): 42
Average Expected Efficiency: 48.61%
Average Achieved Efficiency: 35.74%
Average MKT CM/DZn: $8.20
Average PLAN TGT CM/DZn: $9.62
Average SEW CM/DZn (USED) : $14.61
MKT Vs Plan Tgt CM Variance: $228.0043 M
MKT Vs Used CM Variance: $1024.7610 M
Plan Tgt Vs Used CM Variance: $796.7567M

Dec’18 to Feb’19 unit-02 DPR summary

Total Sewing quantity: 4.14 M PCs
Average MKT SMV/PCs: 9.30
Average Sew SMV/PCs: 9.05
Average Layout MP(OP+HLP): 37
Average Used MP(OP+HLP): 33
Average Expected Efficiency: 43.08%
Average Achieved Efficiency: 52.08%
Average MKT CM/DZn: $8.68
Average PLAN TGT CM/DZn: $12.84
Average SEW CM/DZn (USED) : $9.87
MKT Vs Plan Tgt CM Variance: $515.6169 M
MKT Vs Used CM Variance: $147. 5045 M
Plan Tgt Vs Used CM Variance: $368.1123 M

Dec’18 to feb’19 unit-03 DPR summary

Total Sewing quantity: 4.64 M PCs
Average MKT SMV/PCs: 9.18
Average Sew SMV/PCs: 8.97
Average Layout MP(OP+HLP): 37
Average Used MP(OP+HLP): 39
Average Expected Efficiency: 43.16%
Average Achieved Efficiency: 39.51%
Average MKT CM/DZn: $8.92
Average PLAN TGT CM/DZn: $12.68
Average SEW CM/DZn (USED) : $16.19
MKT Vs Plan Tgt CM Variance: $508.2320 M
MKT Vs Used CM Variance: $982.4476 M
Plan Tgt Vs Used Tgt CM Variance: $474.2156 M

*Data Source

Data based on the Daily Production Report(DPR)
CM based on Finance dept. report
CPM based on Finance dept. data (.0358 $)

CM Variance

Unit Wise CM Variance

Buyer Wise CM Variance

Average Marketing VS Average Used CM

Average Plan Target VS Average Used CM

Findings from Analysis

CM loss at Marketing $3,933.0123 [Dec’18-Feb’19]. Only Buyer ‘Promodoro’ Marketing CM gain $5.8259.
Average Marketing SMV & Average Sewing SMV difference 0.21. SMV used in production less than Marketing, which is a positive fact to gain profit.
CM loss of Unit-01 & Unit-03 in production, use of more manpower than Marketing, the achievement of less efficiency than Marketing are the reasons for the loss in CM.
In Unit-02, efficiency gain (52.08%) is more than expected (43.08%) but used CM is more than Marketing & Less than Plan target CM. If there was no loss during Marketing, CM gain would be profitable.
Efficiency variation avg 2.40% than expected which results in total CM loss.

Feedback from Analysis

CM based target need to establish for-profit gain in CM.
The capacity calculation/ projection should be followed by CM considering SMV, Manpower, Working hour, Efficiency as well as Quality.
CPM should be standardized/similar for all buyer & all units.

The Necessity of CM Based Target Set-up

Currently, Garments profit calculation based on FOB. But in practice, it is the total performance of Textile, Fabric finishing, sewing, printing, embroidery, Garments finishing, logistics, etc. & investors profit percentage, deficiency cost.
Profit calculation & evaluation will be equal for all units.
CM based target can be used for other units like Textile, AOP, Finishing, Dyeing, etc. to measure performance more precisely.

Pre-activities for CM Based Capacity Allocation which we Want to do for Future

Production floor should be Industrial Engineering database controlled.
6S/7S Training & auditing system should be established for all employees of all departments.
Floor IE must know operation breakdown, CM & Efficiency analysis.
Line balancing, workstation standardization, lean management training needed for IE & production people also.
No modification in Line layout (SMV, MP, M/C) will happen by approval of Corporate IE department.
The cutting section should be IE based CM calculation to improve efficiency & gain profit from Cut-make section.
Finishing section should be IE based CM calculation to improve efficiency & gain profit from the make-trim section.
The textile sector should be IE based to reduce re-process & re-work. In the long run, it will gain more profit from the textile sector.
Printing IE activities will be vast to CM based capacity allocate for making it more precise in profit gain & efficiency achievement.
Other production units need to Industrial Engineering controlled to achieve target efficiency & profit.

A Positive Outcome from Proposed Implementation Ideas

There will be no CM loss during marketing stage. Use of similar CPM will lead the marketing team to work for plant target CM wise order taking.
CM loss will not happen in the production stage with proper manpower utilization, efficiency achievements; quality products by IE based production system.
CM profit is the core profit percentage of FOB & our factory profit margin will increase by proper implementation of IE-based activity in every sector.

CM Analysis Presentation Download

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

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Operation breakdown, SMV and layout of Shirt Manufacturing

SMV Summary of Shirt Manufacturing

Man Power Summary of Shirt Manufacturing

Machine Summary of Shirt Manufacturing

CM Analysis and Feedback of Garments

CM Variance

Unit Wise CM Variance

Buyer Wise CM Variance

Average Marketing VS Average Used CM

Average Plan Target VS Average Used CM

Findings from Analysis

Feedback from Analysis

The Necessity of CM Based Target Set-up

Pre-activities for CM Based Capacity Allocation which we Want to do for Future

A Positive Outcome from Proposed Implementation Ideas

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