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Showing posts from October, 2011

How to Reduce Line Setting Time in an Assembly Line?

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Engineers and production managers always look for a way to improve the factory’s labour productivity. But they look over things that lower labour productivity. “Higher line setting time” is one of the most visible reasons at present that reduces factory’s overall productivity. When it takes a longer time for setting a line, most of the operators sit idle. That means operators are not utilized in producing garment and operator productivity falls resulting in high labour cost. Following piece of article will help you to reduce line time.

I have seen factories where 1.5 to 2 days are spent in line setting for woven tops. When line supervisor and engineers are asked why they are taking that much time to set a 40 machines line, they give dozen of reasons. Whatever reasons line supervisor have, is the root cause for the delay. Reasons may vary from time to time or style to style.

Why a line setting takes longer time Let’s discuss the main points that cause longer time for line setting.   Fac…

How to Calculate Machine Requirement for Sewing Operations in an Assembly Line?

You may often to need estimate machine requirement calculation. In this post I have discussed the steps to estimate how many machines and what types of machines you need to make your garment in an assembly line. The primary information you need for calculating number of machines -

A. Daily production target – it means how many pieces you want to stitch per day.

B. Number of hours in a shift – How many hours you plan to work each day

C. SMV of each operation – Standard minutes for each operation

D. Present efficiency of the factory (in case you don’t aware about present factory efficiency, use 50% efficiency). Efficiency is required because production will depends on how efficiently workers may do their job.

Step 1: Operation breakdown 
Select a garment for which you want to calculate machine requirement. Analysis the operations required to sew the garment and list down operations in a spread sheet in a sequence. For example, see operation break down of a Crew n…

How to improve seam performance against slippage in garments?

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Home > Garment &Textile Testing
Seam slippage is one of the causes of seam failure that affect appearance and performance of the garment. Seam slippage occurs on woven fabric, when yarns slide together along other yarns or a line of stitching. Seam slippage occurs with a low stitch count, insufficient tension on threads, or improper stitch and seam selection.

Articles on Industrial Engineering - 2

15. How to Control Apparel Production Cost?
I was in a meeting discussing about line efficiency, present cost per pieces and what the production people can achieve to lower down the making cost. When we started discussing the fact and figures everybody was surprised. Read more...
16. How to calculate Machine requirement for garment to be made in an assembly line?
Follow the following steps to estimate how many machines and what types of machines you need to make your garment in an assembly line. The primary information you need to calculate number of machines are Read more...
17. Which Machines are needed to make Basic Polo Shirts?
Five types of machines are used in making basic Polo Shirt . Machines are Lock stitch (Single Needle), Over edge (Over lock), Button holing, Button attaching and Flat lock (Flat bed). Read more...
18. Which Machines are needed to make Basic Tee Shirts?
Three types of machines are generally used for making Basic Tee (Crew Neck) in mass production. Machines are…

How to Give a New Look to Your Old Clothes?

A quick and easy way to alter the way old clothes look is to change the cut. If you have a long sleeve dress or top that is frayed at the edges, convert it into sleeveless one. The same can be done for long pants and jeans by making them shorts and capris. Add a pretty brooch to your top or stitch on a lace collar and see the difference.
The color of most clothes fades over time. If you don’t want to let go of your favourite garment, get it dyed a bright and beautiful color. A red or deep blue can make your clothes look new.

Accessorising an old dress or tee can make all the difference. Utilize smart belts, neckpieces or even a lacy hem to make your garment look good.

If you are all out of ideas, go to your local tailor for help. He/ She will have some embroidery pieces, patches, stylish buttons or zippers that can transform your outfit. Ask him for suggestions or take along pictures of the idea that you have.

Jeans that are already faded can be made stylish by adding rips in the …

Standard Operating Procedures (SOP) for 'Garment Component Fusing' Process

To control fabric shrinkage and other problems like peeling, bubbles etc. occurred due to fusing process to certain garment components, following SOP (Standard operating procedures) must be followed. This SOP is used by garment manufacturer.

Costing and Negotiation Skills for Merchandisers

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This is a guest post contributed by Anjuli Gopalakrishna

It’s that time of the year again. The beginning of a new season, proto sampling deadlines, endless coordination with fabric suppliers and garment vendors to stick to the dates to make sure the samples reach in time for the ‘ oh so important meeting’, and above all costings, costings, costings. If you are a merchandiser in the apparel arena, you can relate to the above. 

A period of crazily hectic activity, and pressures mounting from all sides...buyers, suppliers, bosses...But there is some excitement in all this mayhem. The thrill of working on new styles, designs, fabrics... the excitement and anticipation of booking new orders... the fun in negotiation and haggling for best prices...Ask any merchant on what they like most about their jobs. And they will tell you it’s these aspects which give them an adrenalin rush in their jobs. Otherwise, life would be pretty mundane... 
Given the crazy workload that hits a merchant at this…

Customer Focused Merchandising (CFM) – Top Ten Tips for being a CFM Merchandiser

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This is a guest post contributed by Anjuli Gopalakrishna of Anjuli Gopalakrishna Training and Consulting.
In today’s extremely competitive apparel industry, CFM – customer focused merchandising is the single most important factor that can differentiate you from others in the field, whichever side you may be on, be it retailing or sourcing as in buying offices or in manufacturing. We cannot afford to be satisfied with just being ‘nice’ to customer anymore. We must aim to offer them an unforgettable experience. This requires not just training, skills and knowledge, but creating an environment where people take pride in serving others. Buyers/Customers are not just buying the product or service from you, they purchase ‘how they feel doing business with you’. It’s the memory they retain of how it was to work with you...and that’s what keeps them coming back to you again.

Why not to request your buyer?, they may like your option.

I am sharing my first experience of handling a small domestic order. That time I just joined in a newly established export house. So, it was also the first order for the company. Still I can remember the name of my first customer. The order was from Molife. They ordered for pink colored Polo shirt for their brand promotion. Order was for only 50 pieces and pique fabric to be used with flat knitted collar.

21 Common Activities of an Export House Merchant

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Merchandising is a part of the garment manufacturing process. In an export house, apparel merchandisers not only do order follow up from the start of order processing to shipping the order. Yes, they do more activities even before an export house receives an order and after shipment.


Followings are the common activities performed by an export house merchant.
Communication with buyers in terms of sample development, approvals, order confirmation Communication with internal departments and forwarding required information to the respective departments Procure order and order confirmationProduct development, sample development and sample approval Development of bit loom, knit down, print strike-off, embroidery strike off etc Style costing and price negotiation with buyer Calculating the consumption of raw materials (Bill of material) Price quoting Lab dip and approval of lab dipSourcing and purchasing of raw materials, Approval of fabric, Trims and Accessories Fabric Testing and garmen…

Apparel Merchandising Articles

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List of Defects found in Garments (Trouser)

When a quality inspector checks a garment for conforming quality of the product, he looks into the garment thoroughly. Inspector tries to pull out all defective pieces from the garment lot. Presence of any major defect in shipment pieces may risky in terms of shipment failure. So checker must have the ability to segregate defective pieces from a whole lot of garment.

Thorough knowledge of various types of defects related to fabric, stitches, and accessories and after processes is must be needed. In the following table, an extensive list of defects found in trouser components has been given for quick reference. A checker may found more defects out of the list.

Fabric Faults and Defects Found in Garments

The fabric is the main raw material for making garments. One must use quality fabric to make a quality garment. If you use a faulty fabric in a garment you will get a defective garment. Fabric defects are detected and faulty fabrics are marked during fabric checking process. Fabric checkers should know the common fabric faults and they must be able to recognize defects.

Let's learn what are the common faults found in greige fabric and processed fabric. Some of the most common fabric faults have been listed in following.

Abrasion Mark: A place in the fabric where the surface has been damaged due to friction or abnormally weakened by any operation through which it has been passed.

Misprint on fabric: In printed fabrics, either missed, or partially missed, or incorrectly positioned relative to each other.

Double Pick: Two yarns running simultaneously, mostly in the weft yarn.

Oil Stain: Oil mark on the fabric.

Hole: A breakage of yarns in the fabric involving more than two yarns.

Bow: When …

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