Showing posts from April, 2015

Digital Displays for Production Status - the Improved Way Communicating Floor Performance

How do you check the production status of a line? Ask your subordinate to show you the data or ignore to check minute by minute reports? Or wait for someone to update your hourly production board.
All these methods are age-old. Display your reports and dashboard on the LCD screen. This is an effective way to monitor shop floor production. Secondly production status will be visible to everyone who is working on the floor. 
Line supervisor or a production manager has basic requirement about production data.  How many pieces are made by the line at this moment since morning? What are the operations wise production? At least production update of critical operation in the line? 
You also need data for the same. If you can provide these data on a digital display board, you don’t need to waste time in report making while you need.

You will say it is not possible to track the production of every minute. Checking hourly report or looking into it every half an hour is not possible. 
With techno…

6 Checklists for Bulk Fabric Cutting

Meeting the planned cut date (PCD) is hard. And you always get an urgent note to start bulk cutting.

If you are in a hurry to start the cutting order and start cutting without checking pre-requisites for the cutting process, you might fall into the trap. Having the fabric in a store is not enough to go for bulk cutting. You must have approvals on few important things prior to layering the fabric on the cutting table and cutting the lay. If you cut fabric without approvals and unfortunately if something goes wrong in production (or shipment) due to cutting mistakes you will be responsible for that. Other than that if the fabric is not approved or if you use incorrect patterns for the bulk cutting, cuttings can’t be used for stitching quality garment. PP sample approval and PP meeting are must be done prior to bulk cutting.

To avoid the risk of making mistakes in bulk production you must consider checking the following things. 1. Approved production pattern A pattern that is made for a…

What is Pilot Run in Garment Manufacturing?

The pilot run can be named as a trial production run. A pilot run is done after approval of the PP sample and before bulk cutting. The pilot run for a style (order) is conducted if the buyer asked for it. Many garment manufacturers set pilot-run as standard procedure. In those companies, Pilot run is must for all styles irrespective of buyer requirement.
Garment manufacturer cut around 100-200 garments per style for the pilot run. This production is done based on PP comments. All 200 pieces are treated as mini production. Factory follows complete processes planned for the order. Factory sets up stitching line. And production for the pilot run is done as it to be done for the bulk production.

Purpose of Pilot run
Purpose of pilot run is to check production techniques and quality requirement. Pilot run pieces are thoroughly checked by factory quality department at every stage of production. Based on the pilot run result bulk production is planned. Through pilot run process, production…

Production Planning and Control – the Concept and Definition

This is a guest post from Ashish Kumar Gupta.

Production Planning is one of the integral parts of any manufacturing unit. The process complexities vary in degree depending upon the number of processes involved in the production of the desired product. With the globalization, the sourcing process has become complex as international boundaries are not a deterrent in conducting the business.

Production planning is a managerial function mainly concerned with the following issues.

What production facilities are required?Layout of production facility to be laid out in the space available for the productionDesired product at the desired rate of production Production planning has a dynamic nature and has to be changed according to the changes in circumstances. Any deviation from the planned parameters as perceived during the initial planning i.e. Machine breakdown, change in raw material, change in demand, change in requirement etc will lead to the change in plan.

Production planning is done…

International GOTS Conference in India (May 22, 2015)

The First International GOTS Conference-‘Strong Partnerships for Success’, to be held on
May 22, 2015, in Mumbai, India.

India is the largest producer of organic cotton (around 70 per cent of the world). It is also the largest processing and export market of textiles using organic fibres. With more than 1,000 facilities, India is also the country with the highest number of GOTS certified facilities worldwide, which makes it actually the hottest sourcing destination for the same. However, even more commitment is required at garment stage to further exploit the potential in this sector.

The theme of the conference is ‘Strong Partnerships for Success’. This event will once again underline and highlight GOTS’ commitment to the Organic Textiles market in general, and India, in particular. 
“The conference will be a great opportunity for all players in the textiles value chain, who are committed to sustainability and looking towards implementing the business case for sustainability with the…

Common Practices Followed to Control Fabric Shrinkage in Garment Manufacturing

Fabric shrinks when it is washed. This is one of the common facts of fabric quality. How much fabric will shrink is not predictable. As fabric shrinkage varies from one type of fabric to another. Even roll to roll shrinkage variation is found for the same fabric and in the same order (due to lot variation). Woven fabric shrinkage (2-4%) will vary from knits shrinkage (3-8%). Shrinkage of stretchable fabric (10-18%) is higher compared to normal woven fabrics.

In this article, I will share common practices followed by garment manufacturers to control fabric shrinkage in the fabric as well as in a garment. To control fabric shrinkage to wash you first need to test fabrics prior to taking any action. Common processes of measuring fabric shrinkage are discussed here.

1. Measure Fabric Shrinkage and add shrinkage to the pattern: 
Garment manufacturers cut fabric swatch from all fabric lots received from fabric suppliers and send to a testing lab for measuring (testing) fabric shrinkage per…

Use Pivot Table and Become Smart in Report Making (Download Excel Template)

Report making is one of the daily activities for most of the garment manufacturers in the garment industry. Most of them use a spreadsheet (MS Excel or Open Office) for making a daily production report and other reports.

I assume that you are one of them. You may know how to use a spreadsheet. The question is how are you utilizing excel tools to make your reports?

Take an example of making Daily production report (DPR). You make it daily, right? How do you do it? I hope you follow this step,

Existing Method of Report MakingYou have DPR template with set formula You copy last day’s sheet and make new sheet. You delete previous day’s production quantity and add today’s productionAdd new rows in the template if need to add more/new style in the reportYou drag the formula to new rows added in the new sheetYou calculate total production by adding today’s productionYou cross-check and tally production quantity with previous reports and actual report twice.
(If you already made 31 sheets da…

Facebook Fan Page