Showing posts from January, 2014

How to Make Garment Inspection Report - Simple Method and Advanced Method

If you are already working in garment production, you might know that garments are inspected at various stages in the manufacturing process. Common Inspection stages practised by garment factories have been explained in this article.

In this post, I will show you how to make quality inspection reports for the manufacturing process. Here the term 'Garment Inspection' means all kind of garment checking other than final shipment inspection.

The simple steps involved in making quality inspection reports
Design quality inspection format(s)Record quality inspection data while inspecting goods - online or off the lineAnalyse data and make a summary of the reports
Do you use minimum formats to record inspection findings? I hope you do. Otherwise, you were not reading this post.

Let come to the main topic. How to make garment checking report (inspection report)? In this post, I have explained simple to the complex form of data collection and report making. Use one that matches your req…

Simple Guides to Keep Sewing Floors Clean

"Please share some effective ways on how to improve and maintain cleanliness in production area. Are there equipment used in order to make the factory very clean? I'm currently working in Cambodia, and I noticed that most of the factories are not clean. Most of the threads, fabrics are present in the production floor." I received this via mail from an OCS reader.
Yes it is true that most of the unorganized factories don't care much about keeping their shop floors clean. This is not only in Cambodia, same scenario exists in other parts of the global apparel industry. Rather than discussing much of cleanliness issue you can start on your own to make it better.

Keeping workplace clean is a way of working and living in a healthy workplace. A clean workplace helps to achieve better productivity and protect worker's heath and safety. 
Here are simple guides for you that can help you keeping your production floor clean.

Encourage workers to always keep workplace clean.Do…

Productivity Study of Shirt Manufacturing (Survey)

Last week I was in a meeting with a group of Garment Industry Professionals. We were discussing about the possibility of shirt production per machine per day for a new start-up company. In the discussion we got productivity figures like 8-20 shirts per machine per day (8 hours shift day). The BIG question is what productivity to be considered.

I did quick research on net and found that Laguna Clothing, a Bangalore based shirt manufacturing company makes 3200 pieces with 200 sewing machines in one factory and 7200 pieces with 350 sewing machines in another factory. That means machine productivity of that company is 16 and 20.6 respectively. Operator productivity of Madura Garments Exports is 11 pieces  in conventional line and 18 pieces in lean module.

I know many of you are working in shirt factories. What is your experience about the productivity level of factories those make shirts (Casual and Formal)?

Table of Contents of the Book (IE Guide to Job Interview Preparation)

Inside the book you will get answers of the following 50 Frequently Asked Questions.

Table of Contents
1. 2.
4. 5.
6. 7.
8. 9.
10. 11. 12.
13. 14.
15. 16. 17.
20. 21.

26. 27. 28. 29. 30. 31.

32. 33. 34.
38. 39. 40.
41. 42. 43. 44.

49. 50.
51. 52.

AEPC Annual Export Award Function 2013

In Dec 2013, Apparel Export Promotion Council (AEPC) of India organized its Annual Export Award function 2013 for outstanding export performance for the year 2012-13, at apparel house, Gurgaon.

Dr. K S Rao, Union Textiles Minister, came to deliver awards in presence of Smt. Zohra Chatterji, the Guest of Honour, Senior Officials of Govt. Of India, Officials of AEPC and the captains of the garment Industry were also present.

Indian top tire garment exporters Shahi Exports Pvt Ltd., Orient Craft Ltd., Gokaldas Exports Limited, Pearl Global Industries Ltd., Silver Spark Apparel Limited and Eastman Exports Global Clothing P. Ltd.won the awards in following 15 categories.

Piece Rate System: Benefits of Group Piece Rate System over Individual Piece Rate System

Piece Rate system is widely used when it comes for calculating payment for the garment factory workers for their work. Piece rate can be defined as how much money (dollar) to be paid to a worker or group of workers for making one garment. Piece rate may be measured for one complete garment or individual operations.

Piece rate can be also explained in term of output. In a Practitioner Briefing, M.L. Phan explained Piece Rate as following.

What is Piece Rate?  The garment industry in Asia compensates factory workers daily based on what they produce, so piece rate (the number of man-hours it takes to make a single garment) is the standard measure of output. Piece rate also is used in price negotiations between producers and buyers because it avoids the necessity to adjust for currency fluctuations and conversions.

Individual Piece Rate:  The number of cumulative man-hours it takes individual operators to produce a single piece of clothing. It disregards quality, i.e., whether or not th…

Industrial Engineering Procedure

Could you please define what is the Industrial Engineering  procedure? I want to know the exact answer. ... asked by Rukshan Answer This one is really a tough question to answer. As I don't know if there is a defined IE procedure for the garment industry. So, instead of defining Industrial Engineering (IE) procedure I would like to explain things for better clarification. 
In garment production, Industrial Engineers do a number of tasks. They use a number of tools and techniques, and methods for the tasks. I would say it is not exactly IE procedure but procedures of implementation of IE tools and techniques. 

IE Work Flow Chart Still if you like to know about IE procedures, it can described with a work flow. Most common tasks of an IE are presented in an order in the following.

Style analysis --> Make operation breakdown --> Thread consumption calculation--> Making line layout on paper --> Select m/c and equipment --> arrange guides and attachment -->Planning fo…

A Sewing Line with Minimum Number of Helpers is More Profitable - How would You Prove This?

QuestionI have started my career as an Industrial Engineer in a Jeans manufacturing company. In past few weeks I had gone through nearly all of your articles on IE on your blog and it has been a great help for me. But, I need some additional advises and I thought your help would be best for me.

I have been given an assignment to reduce helpers in the sewing department. Managers have observed that in many operations together with a machinist, a helper is also provided. Thus, this increase cost and consume time as the helper could have been placed to work as a machinist. Therefore, I want to know what method to use to show the line managers that it would be more profitable to reduce helpers from the floor. ... asked by Tashreen from Mauritius.

How to Calculate Lead Time for Stitching Process?

For a long time, I did not publish any answer of the questions asked by OCS readers. This week I will post only Question & Answer posts. Keep reading for the latest posts on Q&A series.

The question I am going to ask is the basic of the manufacturing industry. 

Q-1: How can I calculate Lead Time for stitching process? 

Q-2: Should we always consider style category proportion (Basic, semi fashion, Fashion & H fashion) while calculating the Lead time for a stitching facility? Waiting for your prompt response. ... asked by Sohaib Abbas

While I was reading this question, suddenly one of my real life stories came to my mind. A similar question I have faced 7 years ago. I appeared in a job interview for production planning job. The interviewer gave me a problem and I had to solve that. Problem was as following  "Suppose you receive an order of 5000 pieces. you have two sewing lines to run the style and average production per day per line is 400 pieces. Calculate…

Juki's Knowledge Center Revealed

There is no end to learning. I continuously hunt for knowledge sources on the web to gain more and more knowledge. Today I discovered one such valuable resources and sharing it with you. It is Juki's web Magazine.

You may already hear about Juki, the world leader in sewing machine technology. Following articles are picked from old magazines, but still, these are a valuable piece of knowledge sources.

Learn basic things about industrial sewing machines. Start reading valuable contents by connecting to the following links and gain some knowledge.

I have picked 5 topics for you. There is articles and case study on managing sewing floor, line layout, Promoting 5S in sewing factories etc. On each title, lists of subheadings have been added.

Enjoy learning!
1. Functions and utilization of the sewing machine with an automatic thread trimmerBasic functions of the lock stitch machine with a thread trimmerThe lock stitch machine with a thread trimmer is evolvingEffects of the introduction …

Thread Consumption Calculation Process for Garments is Simplified

Calculating Thread Consumption of a garment is one of the common processes in garment manufacturing. It was never an easy task to find an average thread requirement for a style in bulk production. First reason, this is a time-consuming process. Secondly, though factories use the scientific method for calculating thread average, most of the time factories source extra threads for production or factories found a lot of leftover threads after style completion.

However, you need to follow the process every day. When you get a new style, extra time needed to understand the operations (construction details). One other important point I like to mention that till date providing thread average is the job of a production guy or an Industrial Engineers.

5 Things You Can Do to Achieve More on New Year

On the new year set your goal high to achieve more in your professional life as well as personal life. You will get the same 24 hours in a day but you need to accomplish more than yesteryear. How to achieve more is the question for everyone. Simply, to get more you have do more things than last year. Make this year remarkable by achieving your goals and set a new goal.

Following are the 5 Things that can help you to accomplish more than you did ever before.
Become a ProUse To-do List at workPrioritize your workDelegate work to subordinateSet time limit to be spent on social networking sites

What is the Difference Between Fix Cutting and Block Cutting in Garment Manufacturing?

In garment manufacturing cutting is one of the very critical processes. If you don't plan cutting method carefully, it might result unnecessary wastage of fabrics. One such factor is whether one needs to cut garment parts in block or as per fix pattern (shape).

Fix Cutting:  Cutting of fabric panels as per final pattern of garment parts. Just seam allowances are added in this case. Bigger parts are normally cut in fixed shape if there is no need of allowance for subsequent processes. 

Block Cutting:  When garment components are cut roughly around a part are called block cutting. Following are main reason for cutting in block.

- Block is subsequently cut very precisely, by various means. Like for small garment components, blocks are cut using straight knife machine and later precisely shaped using band knife machine.

- Block cutting might be done for splitting the lay, to assist handling to the band knife.

- Another reason for block cutting is allowing handling of garment compo…

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