Showing posts from September, 2011

Articles on Sustainable Clothing

Adidas Group committed to have 100% Sustainable Cotton by 2018

Adidas, one of the top sports wear manufacturers, is stepping forward to have 100% “Better Cotton” in their products by 2018. In the ‘Corporate sustainability Report 2010’ Adidas has discussed their group-wide goal and approaches to become sustainable clothing manufacturer or zero-emission Company. This initiative will be taken across its brands – Adidas, Reebok, Taylormade and Rockport.
Adidas Group strategy 2015: “Building on several environmental initiatives over the past years, in 2010, we have developed a coherent environmental Strategy for the whole Adidas group. The environmental Strategy 2015 aims to reduce our environmental footprint 15% by 2015 relative to sales. It follows a clear vision and mission and sets targets to be reached by 2015. These targets cover our whole value chain from product creation to sourcing and manufacturing and from our own operations to our stores and all other sales points.” Source: Sustainability Report 2010, Adidas Group. Company’s specific goal to …

Standard Minutes (SAM or SMV) for Few Basic Garment Products

Can anybody estimate SAM (standard allowed minute) of a garment without seeing and/or analyzing the garment? No. It is not possible. To estimate SAM you have to analyze the garment carefully and check different factors that affect the SAM. SAM of a product varies according to the work content or simply according to number of operations, length of seams, fabric types, stitching accuracy needed, sewing technology to be used etc.

Which Production System is Better - A Conventional line Or A Modular line?

In an earlier post “Garment Production Systems” I have explained that each production system has benefits over others depending on order size, product type, technology level and skill level of the operators. When it comes lean manufacturing system in apparel making, factories start implementing modular system whatever product they might produce. It is true that in a Lean environment, the modular line is most effective than a conventional line if the modular line is run scientific way. Here conventional line means progressive bundle system which is also known as the assembly line. 
To support the above statement, I will take example of Madura Clothing’s shirt line. Recently in a conference (2011) Mr. Lal, Head of Manufacturing, Madura Clothing, presented a case of the Shirt line. They have both a conventional line and Modular line on the same floor.

According to his presentation, in Modular line, they produce 14.3% more shirts with 23% less sewing operators comparing to the conventiona…

How to Calculate Operator Efficiency at Work?

In apparel manufacturing, skills and expertise of a sewing operator are being presented in the “Efficiency” term. An operator with higher efficiency produces more garments than an operator with lower efficiency in the same time frame. When operators work with higher efficiency, the manufacturing cost of the factory goes down.

Secondly, factory capacity is estimated according to operator efficiency or line efficiency. Hence, efficiency is one of the most used performances measuring tools. So how do you calculate operator efficiency in the factory? To calculate operator efficiency you will be needed standard minutes (SAM) of the garment and operations your operator is making. Use the following formula and calculate operator efficiency.

Efficiency calculation formula:
Efficiency (%) = (Total minute produced by an operator/Total minute attended by him *100) Where,
Total minutes produced = Total pieces made by an operator X SAM of the operation [minutes]
Total minutes attended = Total h…

How to Calculate Efficiency of a Production Line?

To know the performance of a garment factory, and a comparative study of the sewing line performance, we measure production line efficiency. So, like individual operator efficiency, measuring the efficiency of a production line is important for a factory. Daily line efficiency shows line performance.

Production Line Efficiency Calculation - Information required To calculate the efficiency of a line for a day, you will need the following data (information) from the line supervisor or line recorder.

1. Number of operators – how many operators worked in the line in a day

2. Working hours (Regular and overtime hours) – how many hours each of the operators worked or how many hours the line run in a day

3. Production in pieces – How many pieces are produced or total line output at the end of the day

4. Garment SAM – What is the exact standard minute of the style (garment)

Once you have above data you have to calculate following using above information -
a. Total minutes produced by the line: To…

How to do Method Study for Garment Operations?

Method study is more of a systematic approach to job design than a set of techniques. It is defined as the systematic recording and critical examination of existing and proposed methods of doing work, as a means of developing and applying easier and more effective methods and reducing costs (Work study definition by ILO). The method involves systematically following six steps

#1. Selection of work to be studied: Most operations consist of many discrete jobs or activities. The first stage is to select those jobs to be studied that will give the best returns for the time spent. For example, activities with the best scopes for improvement, those causing delays or bottlenecks or those resulting in high costs.

#2. Recording of all relevant facts of the current method: Method study uses formal techniques to record the sequence of activities, the time relationship between different tasks, the movement of materials, the movement of staff. There are many techniques used in method study.


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