Recutting in apparel manufacturing

The process of cutting a panel again to replace a defective cut panel during cutting process is called recutting

In most garment factories hundred percent of big cut panels are inspected for fabric and cutting defects, while smaller cut panels are not inspected. Since defectives are found after cutting the fabric, Endbits  (remnants) recovered from lays or leftover fabric are used for recutting.

How fabric consumption for recutting is calculated ?

Continue reading “Recutting in apparel manufacturing”

Types of garment production systems

Garment production system is defined as a structure in which machines, material handling, people and production processes are integrated to convert fabric into garments.

Types of garment production systems differ from each other by following factors:

  1. How many operations does one sewing operator perform?
  2. How many pieces flow together in the sewing line?
  3. How are material transferred from one workstation to other?
  4. How many pieces flow together in the sewing line?
  5. How many machines does one sewing operator operate?
Continue reading “Types of garment production systems”

Reduce Matching Time in an Assembly sewing line using workaid

I was doing my apparel internship with one of the top jacket manufacturer . There I found that lining – Body – Sleeve matching was one of major bottleneck in production. Matching operator would pick up sewn front, lining and sleeve hang them all up on an iron rod. Then she would pick up one front body piece and search for matching lining and sleeve. At one point of time there used to be atleast 50-100 lining and sleeve. So finding a particular number lining , sleeve from a stack of 50 -100 would take a lot of time . Clearly this is a highly inefficient process which affects loading in assembly line . To solve this matching /pairing problem many apparel manufacturers make use of pigeon holes.

Continue reading “Reduce Matching Time in an Assembly sewing line using workaid”

Line balancing in garment industry and how it can be improved ?

line balancing in garment industry is the technique of levelling output of every operation in a garment sewing production line.

The main objectives of balancing the line is to produce the same expected output at every process of an assembly line .There should neither be accumulation of work between two process nor absence of work between the processes. It is important to maintain this balance because in an assembly line output of one process is the input for other.

If a production line is not balanced then there would be following production problems:

Continue reading “Line balancing in garment industry and how it can be improved ?”

Difference between Lycra and Spandex

Difference between Lycra and Spandex has baffled many people in this post we are going to compare spandex and lycra to clear the confusion.

Specific garments or clothes come with inbuilt stretchability qualities. This excellence of the material is due to the existence of spandex.

The content of spandex present in the material is often interchangeably used with Lycra. Most people generalize or evaluate lycra as the synonym of spandex. However, there is a minor distinction between Lycra and Spandex.

Continue reading “Difference between Lycra and Spandex”

Ex factory date and Ex factory : related facts and opinions

Ex-Factory date and Ex-factory are one of the most used but misunderstood term in logistics of manufacturing business. Theoretically there is no incoterm mentioned as Ex-factory, but over the period SMEs related to export-import business have made this an understood term parallel to ExWorks.

Continue reading “Ex factory date and Ex factory : related facts and opinions”

Improving line Layout in garments factory for efficiency.

Improving the line layout should be the first priority if you are trying to improve the productivity or efficiency of the factory. This is because improved line layout is the foundation over which an efficient garment factory is made. In this article we will be talking about planning and improving line layout in garments factory in such a way that the productivity and efficiency is improved. To do it is important to know what is a good line layout.

Continue reading “Improving line Layout in garments factory for efficiency.”

How to improve efficiency of a sewing line ?

Efficiency improvement of a sewing line is a probably the most important performance indicator of garment industry but it is also one of the trickiest. The reason for that is that all the factors that affect increase in efficiency are interrelated.

Continue reading “How to improve efficiency of a sewing line ?”

Acceptable Quality level(AQL) sampling for garments quality inspections

Inspecting 100 % of the garments is time taking and practically impossible for manufacturers or buyers as the order quantities are higher in the garment industry .So there is a need to mathematically find out the optimum number of products (garments in this case) which can be inspected to judge the quality of the whole order. That is where AQL sampling comes to play.

Continue reading “Acceptable Quality level(AQL) sampling for garments quality inspections”