Showing posts from September, 2012

How to Do Skill Upgrading for Machine Operators?

Upgrading of skill to an operator can be done in various forms. It may be building skill in a different machine – one who can handle single needle machine train him to handle a over lock machine; building skill from single operation to multiple operations, building skill from easy operation to make a difficult operations – one who is skilled in straight stitch train him to make curve stitch . Skill to be imparted to a machine operator depends on the demand of a sewing line.

Line Efficiency: A Magical Measure for Garment Manufacturers

Line Efficiency! Sewing line efficiency!

How do you use efficiency figures?

Is it only a factory performance measure? Or

Is it a Key phrase to market your company? Or

You don’t know how to deal with the factory’s line efficiency.

I assume you measure line efficiency of your factory. What do you do with your line efficiency data? Just compare one line to another in a floor producing the same product? Or use it for setting per minute labour cost? Or use it for the capacity planning of your unit?

To me, efficiency is the Mantra, a magical measure (performance indicator) for a factory. Through pushing line efficiency upward one can build up his business and make a massive profit. One can bring discipline to the organization. With this single measure, one can control the cost of the company. I will show you the reason why it is a Mantra to me.

Do I need to remind you how to measure line efficiency? I love to repeat it.

Line Efficiency % = Total minutes produced by a line*100 / Total…

Minimum Wages Update in NCR, India. Year:2012-2013

State government updates minimum wages of workers in each year. Some states do it half-yearly or quarterly. In this post the recent updates (2012-2013) of the minimum wages for the Readymade Garment Industry workers in NCR (National Capital Region) has been shown in the following tables.

Each state has different ways to calculate total daily wages.

All wages are in Indian Rupees (INR). 1 US$=53 INR (on 12/10/2012)

Workers are generally categorized as Unskilled, Semi-skilled and Skilled. Though categorization may vary state to state. The following data table will help to compare minimum wages of 3 states in National Capital Region.

Bundle Tickets, Individual Performance Bonus and Grouping of Operations

Question:Can you describe how bundle tickets should be created so that individual performance bonus system can be implemented. What operations should be grouped together for what bundles? ...asked by Raymond 

Performance-based bonus system
In a performance-based bonus system, operators become eligible for bonus earning when they reach the defined target performance level. The performance of sewing operators generally presented in efficiency%. 
For individual operator performance bonus, you need to track output (in pieces) of an individual operator or calculate SAM produced by individual operators in the given work hours. You can even manually collect daily production of each operator (single and well as multiple operations). Later, multiply production quantity by operation SAM to calculate produced SAM by an operator. Bundle Ticketing I don't know what system you are using at present in your factory for individual operator production tracking. If you can share information of pr…

How to Remove Defective Parts or a Ply from the Lay?

Question: How to deal with the problem when we got holes in layering? ... asked by Fitsum.t

It is normal that you may found defects like holes or cut in the fabric at the time of layering. But defective garment components should not move or pass to stitching floor. In this article, I have explained the way how you can resolve this issue. 
The standard procedure of fabric checking is to mark holes or other defects with a red sticker or visible coloured chalk. It is done this way so that layer-men know where in a layer a defect is located. Once defects are get noticed based defect size a layer-man take decision on how to handle defective layers. If your fabric checker does mark the defects in the fabric during checking, ask them to follow this method. Otherwise, layer-man can skip defects at the time of layering and there is a chance of having bundles with defective panels. 
When you found holes in a fabric layer during spreading of the fabric you have two options to get cutting without…

How to Allocate Sewing Operators in Different Styles?

Question: How to allocate operators for different styles? ... asked by Fitsum.t

Normally, allocation of sewing operators is done based on the skill required in an operation, machine type to be used and performance required.
For example, you may have two operators who can operate the same types of machines or operations but they have different performance level (individual efficiency) on that machine. So, you have to plan according to the work content (operation SAM) and skill requirement to allocate the best suitable operators. For the better understanding of skill details of the existing operators, you can create an operator skill matrix which will help you in easy selection of operators.

You have mentioned operator allocation for different styles. Do you mean your style has a different set of operations? If so, you will get 80% similarities in operations and machine types (As per Pareto’s 80/20 theory).

So, don’t worry about different styles. With your existing operators, you can ma…

What are the Parameters for PU Fabrics?

Question:What are the parameters for PU fabrics, basically for Mumbai climate such as (pealing strength)? ... asked by Bhavesh

Parameters for the polyurethane (PU) fabric depends on the end use of the fabric. I mean which product you intend to make with PU fabric. You have mentioned Mumbai climate. I am not familiar with Mumbai climate. Rough guess are looking for parameters for water proof but air breathable fabric?

How Line Supervisors do Hourly Target Follow up?

Question: How line supervisors do hourly target follow up? ... asked by Fitsum.t

To manage the line performance line supervisor must do follow up whether hourly target is met or not. If a supervisor want to know what is the line output per hour then it is easy. He can count pieces physically or ask helper to count stitched pieces and note down hourly report in a board. But actual control can be done only by taking hourly production figure of each operator. There are various ways to know operator wise actual production in the last hour or from morning to till hour. 

Importance of Quality Control in Garment Manufacturing

The garment industry has a complex supply chain where garment makers source materials, stitch garments and sell goods to retailers. Through buyers and retailers quality garments reach to end user located all over the world. No wearers will buy a garment with poor quality and visible defects. So buyers and retailer knowingly do not purchase a product that does not meet the quality requirement. Quality conscious buyers have a strong quality inspection system in place to avoid purchasing of defective goods.

There is no way garment manufacturers can ignore producing quality products. Quality comes first to most of the manufacturer supplying garments across the countries.

The question is "what is the importance of Quality Control?"

This article is written on importance of quality control garment manufacturers point of view. Quality must be controlled during processing whether it is done by the operators, supervisors, pressman, garment packers or one employs a checker or inspecto…

What is the Difference Between SAM and SMV?

I have been often asked this question - What is the difference between SAM and SMV? by industrial engineers.

They expect me to explain them the correct answer. To be honest, this question was also in my mind for a long time. But didn't have correct answer. I didn't argue with it like many other engineers and use both terms as same. Even many readers of this site asked me the same question again and again. But I delayed posting the answer as I did not have right answer earlier.

I found one article in a magazine Stitch World,where Prof. Prabir Jana and Paul Collyer explained the difference between Standard Allowed Minute (SAM) and Standard Minute Value (SMV). I found it is very interesting and I think what they said is real fact. So I’m sharing it with you.

In the article, authors explained the difference as: “There are three schools of thoughts:
First, both are same;  Second, SAM is an extension of SMV; and  Third, SAM and SMV are completely different measures.

In all work stud…

How to Control Garment Rejection Rate in Garment Manufacturing ?

Question:Please advice how we can control the rejection percentage from cut to ship. What is the way/ procedure/system that can help us to improve our rejection percentage? Please suggest. ... asked by Raju Singh

In garment manufacturing, it will not be a surprising thing if we found few rejected garments after shipment. Reason, most of the manufacturers believe that garments are soft goods and non-repairable defect may occur due to low quality raw materials or faulty process or employee casual behavior. However factory must have check points to control over this issue.

Operation Breakdown and Machine Layout for Bra Manufacturing

Please post an article on operation breakdown and machine layout of a standard bra. I was unable to find anything on the Internet. ... asked by Isuru.

The following operation breakdown of a bra refers to a particular style. Note that, SAM values of the operations may vary according to the style, seam length, attachment and work aids used and machine type.

Prior to use below mentioned SAMs and operation sequence, discuss it with your engineers. I have attached the machine layout of bra making in an assembly line. To improve machine utilization few operations are clubbed together. 
Operation Breakdown: Bra  
OP #SEWING PROCESSSAMMACHINE1Join Cups0.57SNLS2Attach Tape to Cups0.73DNLS3attach Elastic to side cups0.443SZZ4Set support Panels0.39SNLS5Serge support panels0.623TOL6Join support panels, cup and front1.52SNLS7Attach coverstitch tape to front0.61DNLS8Join backs to cups0.55SNLS9Attach coverstitch tape to sides0.47DNLS10Attach lace and tape to cups0.76DNLS11Attach …

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