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Showing posts from March, 2012

Questions & Answers #2

1. Chanrda Shekar asked:  Please advise how to convert from KGs to Yards. Suppose if supplier gives price per KG, how I can convert it to yards. Secondly, suppose if we get consumption in yards, how to convert the consumption to KGs. Kindly advice through formula.
Normally, price of knitted fabric is presented in per Kg. and price of woven fabric is presented in per yard or per meter. However if you need sometimes you can use the below formula to convert fabric price per Kg to price per yard.

  Price per Yard= (Price per kg X Width of the fabric in meter X GSM)/1094  
Example: Fabric price INR 300/- per Kg, GSM 200 grams, Fabric width 1.2 meters.  So Price per yard = (300 X 200 X 1.2)/1094 = INR 65.81/- (Please note that result may vary a little from the exact price due to high density of yarn in selvedge.)

For the second question follow below steps to find consumption in Kgs  Convert yards to meters. Multiply yards by a factor 0.9144. (e.g. garment consumption per piece in length is …

Trims and Accessories Inspection Procedures

Do you inspect the trims prior to attaching those to your garments?

You can set inspection procedures for the trims and accessories as following. Like garments, trims are not checked for 100%. Quality inspector only needs to confirm that bulk trims are sourced as per required standards. Only trims or accessories that are made by manual processes are required to check 100% of quantity.

All the trims are made in the machine are considered as same quality. Like shades of threads, printed text on labels etc. In trims inspection, it is not just visuals inspection of the trims but many times you need to check its physical properties. To ensure physical properties are as per standards, trims are processed for in-house tests. Store personnel, testing lab (if test lab is there), merchants or R&D department can be involved in the tests.

Prior to start inspection, the quality checker must have approved standards of the trims or style wise approved trim cards. Standards for the properties ar…

How to do Line balancing using Operator Skill History?

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In the first article of line balancing method, I had discussed how the traditional assembly is balanced after line setting and the line is running. Here I have explained the second method of production line balancing using operator skill matrix. 

The prerequisite of this method is to have a skill matrix of sewing operators. Normally, at the time of line setting, operators are selected based on their experience on operations. The calculated skill level of the operators on the operations is not considered at all.

As a result, after a couple of hours, high skilled operators start sitting idle and low skilled operators stuck with their work. This line becomes imbalanced and a lot of productive time is lost as operators sit idle. To utilize operator’s maximum capacity, work allocation must be done based on operator’s potential performance level (efficiency) and work must be shared with operators who have excess capacity.

To get a balanced line from day one, select operators for the operat…

What is skill Matrix for Sewing Operator?

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Home > Industrial Engineering
Skill Matrix is a chart or a database where operator’s past performances on various operations are recorded in a systematic way for the future reference. In a skill matrix operator performance is recorded in efficiency percentage. Skill matrix is also called as skill inventory of the operators. A basic skill matrix is shown in Figure-1. (Click on the picture for zoom). Skill matrix is updated on a regular interval. Or after completion of each style operator's current performance (efficiency%) updated on the database (for manually developed skill matrix).

Figure-1: A Basic Skill Matrix developed in spread sheet


The benefits of an operator skill matrix are enlisted below.
It keeps record of all operations an operator had done in the past and efficiency level in each operation. Engineers / line supervisors need minimum time to find and select most efficient operators for an operation from the pull of operators. For line balancing, operators can be sel…

Apparel Case Studies

This is a database of e-publications, Fact sheets, Articles and Case Studies related to apparel industry. This is an initiation to supply you wide range of reading materials. All documents listed here are available in the web. The link will open on the server owner's site. You can read and download these articles.

Updates: Most of the case study and article links are removed from this page, as most of the sources do exist current / removed by the sources.
Lean Manufacturing
Improving Productivity and Profitability by TBM Consulting GroupLean Manufacturing in the Apparel IndustryApparel Production
Improving Labor Productivity in Egypt's Ready-made garment sectorProductivity in Indian Apparel IndustryHow people propel Productivity at Levi StraussProductivity and competitiveness of Indian Manufacturing Sector: Textiles & GarmentsGuideline for Fabric Store and Cutting Room managementSewing operator recruitment and training


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