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Showing posts from November, 2018

How to Calculate Overall Line Efficiency?

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In the garment manufacturing industry, we measure line efficiency on daily basis. Out of different KPI for efficiency measure, the overall line efficiency (simply Line Efficiency) is majorly measured by the garment factories. In this post, I will show you how to calculate overall line efficiency in a garment unit. Let me first explain what the overall line efficiency is.

Overall Efficiency When operators are on the shop floor, sometimes they will work on the standard jobs, sometimes they will work on off-standard jobs and sometimes they may not be doing any job due to lost time (unavailability of work). In a day, each operator is given 8 standard hours for the work. The 8 hours shift time can be separated as standard work hours, off-standard work hours and lost-time hours. When the whole shift hours are used in the calculation, irrespective of how much time (hours) operators do an off-standard job and remain idle, it gives overall efficiency. When you calculate overall line efficienc…

Graduation Research Project Ideas for Fashion/Apparel Technology Students 2019

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It is time to prepare the concept note for the research project you will be doing in your next semester. I am sure you are doing research for finding a good project topic that should sound interesting, trendy as well as can add value to the industry. The project is named as graduation project or research project.



After researching current trends and development happening in the fashion industry and fashion supply chain, I have prepared a list of interesting and valuable topics. You can pick one of those if you find it interesting to you.

Many of you will be interested in innovative topics. But for the valuable and innovative project ideas it takes time to complete the project and in many cases, it is not possible to complete a project in 5 months. So, while selecting a topic you need to be careful about project outcome/deliverables, value addition to the industry, the possibility of getting a good score in the final jury.

List of  the latest project topic ideas 1. Developing an altern…

Answer to Quality Control Job Interview Questions in the Apparel Industry

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In an earlier post, I had published questions asked in the quality control job interview. Today, I will post answers to those questions. Answers to some questions are subjective and depend on the actual situation of your work experience and learning. I will try to explain the possible answer to all these questions. The answer will help you to be prepared for your next interview. As you are applying for the QA manager position, I am assuming that you already know the apparel quality control system. 

To read the answer click on the question.
[accordion]1. What kind of products have you handled in past?There is no fixed answer to this question. You need to tell the types of garments you handled in the past and you are currently handling.

If you are already working in a garment factory, you know what kind of apparel products you are making. You just need to name those products. For example, Shirts, knitted tops, ladies dress, woven blouse, trousers, suits, designer dress etc are example dif…

How to Prepare an Effective Sample Inspection Report for a Factory?

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Sample making, sample checking and sample approval is part of sourcing apparel products from the garment manufacturers. Know how to make an effective garment sample inspection report on the sample checking. I have written this article to answer the below question.
I need to write a report for the factory on a sample they have made for me. Can you send me a format template for such a report? In the past, I have written reports and the factory still does not seem to correct the errors mentioned in my report. There must be a format that is easy for any factory understand.
Factory team may skip your comments of the error you have mentioned by mail or a written document. Sometimes without the physical sample and images of the sample, understanding the error in a sample is difficult. Secondly, in a garment factory, merchandisers and QA are always busy with their work.
To get a sample with reduced error, the first step you need to do from your end gives them clear instruction about the produ…

Apparel on Demand Solution by OnPoint Manufacturing

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On-Demand manufacturing plays an integral role in the evolution of the apparel industry. While the biggest disruption will undoubtedly come from innovative software that will allow all of our systems to be seamlessly integrated, On Demand manufacturing will impact everything from samples to the customer experience, adding value every step of the way.


More specifically, On Demand solves issues such as out of stock, out of inventory, out of the right size, color, hem length, sleeve length, etc. On Demand adds value to the customer, brand, and retailer by producing exactly what is needed, when it’s needed.

Related: Gerber Launches FashionTech Platform 1.0 in Collaboration with OnPoint Manufacturing

In addition to addressing inventory challenges, On Demand has an immediate, positive effect on reducing the apparel industry’s contribution to pollution. It is said that this industry is the second worst polluter in the world. It is caused in part by producing clothing based on an unscientifi…

Importance of Post Shipment Garment Costing in the Apparel Industry

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Understanding what price to charge a buyer is an important decision in any industry. Charging less than the manufacturing and operational cost is bound to create losses for the company while overcharging will make that same company non-competitive. Therefore, many companies hire industry experts to develop product cost and pricing strategies.

Further, many companies invest in sophisticated software such as Gerber and Sew-Easy to calculate the most accurate Standard Minute Value (SMV) to provide the best efficiency while training employees and managers on various management systems, such as Lean manufacturing.

How product costing is done? In a typical apparel manufacturing plant, the responsibility of costing falls to the account manager. However, often costing is delegated to a development and costing merchandiser. If an inquiry comes from a well-organized buyer, that buyer provides a Bill of Material (BOM) that accurately lists the fabric and other accessories required to make the pr…

Industry 4.0 in Apparel Industry - An Introduction

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With the ever rising growth of demand in apparel, the very idea of manufacturing had to be reshaped. This need brought about a change from a full labour-intensive industry to manufacturing done through automation. This topic will talk about what is industry 4.0 in the apparel industry and how it is impacting the fashion industry.


What is Industry 4.0? Industry 4.0 is the common term for modern industrialization. This is leading to automation and data exchange in manufacturing technologies. It includes entities like cyber-physical systems, internet of things (IoT), cloud computing, artificial intelligence (AI) etc. All these tools have made it possible for what is called ‘smart factory’.

There are four main pillars of Industry 4.0 such as augmented reality. These 4 pillars help companies avoid errors by enabling them to manage inventory at real time; additive manufacturing such as 3-D printing and robotics which allows the companies to produce faster; big data, like IoT enables with da…

Production per Machine for a Formal Trouser & Formal Shirt

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Question:What should be the Production in Pcs/Machine for a formal trouser & formal shirt? ... asked by Naushad Production per machine in a specified duration is known as machine productivity in the specified duration. There is some benchmark for machine productivity for both trouser and formal shirt in national level as well as international level. But that productivity figure varied widely depending on the technology used by the plant in manufacturing the products, semi-automatic machines, upper head material movements to name a few.



Productivity Benchmark of Shirt and Trouser  However, for your knowledge, formal shirt productivity figure is 9.12 units/ machine per 8 hours shift day (National benchmark, India) and 20.87 units/ machine per 8 hours shift day international benchmark (Hong Kong).

For trousers, national and international figures are 6.84 units/shift and 19.25 units/ shift respectively (ICRIER, 1993). Average machine productivity on base technology is 8.07 units per s…

Denim Finishing Using Laser Technology – Its Advantages and Disadvantages

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The Laser Technology for denim finishing/washing With efficiency and sustainability driving the apparel industry, the process of denim and jeans finishing is taking a drastic change from its traditional method. Alternative methods of garment finishing, washing, the chemical process which will have minimum impact on the environment from denim industry have become a top priority. This article will focus on the use of Laser Technology on denim finishing which has the potential to make a change from the traditional way to something which is more modern and environment-friendly.


What is laser technology? Lasers have long been used in the apparel industry for laser marking (for surface fading), laser welding (for joining two or more layers of fabric through melting it), laser engraving (controlled cutting to a depth), laser cutting (for cutting through the fabric). It is a device that generates an intense beam of coherent monochromatic light by stimulated emission of photons from excited a…

Different Departments in a Garment Factory and Their Functions

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You may already know what a garment factory is in the apparel and fashion industry. Garment factory is a place where complete garments are made from the fabrics following a chain of processes. A process flowchart will give a better idea of how things are done in a garment factory. As mentioned in the title, this article will show you the different departments of a garment factory. Departments are set-up based on the group of activities to be performed by a team of people.

Further, we will see the various functions of the different departments of a garment unit. Garment manufacturing is a complex process which starts with sample development and end after shipping the finished garments to the buyers.



Different departments of a garment factory Here is the list of garment factory departments. These departments include the pre-production departments, production and post-production departments. The supporting departments are also listed here.
Marketing and business development department Des…

Live Tracking of Production Lines in Garment Manufacturing

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The real-time production line tracking tool and system is the primary need for digitizing shop floor production data. Avadhesh Tyagi, Director at Uditya Tech Private Limited shared about Uditya tech solution for live tracking of production lines data and system workflow.



The software is a simple, very effective and proven system for “Live Tracking of Production Lines”. This system does not need RFID tag or Barcode tag or Touch button to track the production quantity from the end of the line.

If you look at the garment production floor, there are several production lines and each stitching line consists of tailors who collectively stitch a garment. At the end of each production line, traditionally, factories check garment prior to sending to another department.

How the Live Tracking System work? The workflow of the Uditya system is explained here.

At the end stitching line, at the checking point, they put a device to count of the garments stitched, garments sent for mending/alterati…

Sewing Machines for Denim Jeans Manufacturing

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For making denim jeans pants, primarily industrial sewing machines are used. Different level of technologies are available in jeans sewing machines. In this post, you will find basic sewing machine as well as latest automatic sewing machines used in jeans making. Here I have shown different machine types. The same machine type are available from many sewing machines brands. For the same machine types and from same company, different machine models are available. This article will cover followings -
List of different types of sewing machined for Best sewing machine brands for jeans manufacturing Application of the listed sewing machines 
List sewing machines for denim jeans making factory Denim fabric is thicker material compared to other clothing fabrics. For handing and sewing denim fabric normal sewing machines as well as heavy-duty sewing machines are required. Following machine list will be a helpful guide for selecting machines for your startup.

#1. Industrial Lock stitch machine…

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