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.

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Sewing line balancing and how it can be improved ?

Sewing line balancing is the art of levelling output of every operation in an assembly sewing production line. The main objective 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:

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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.

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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.

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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.

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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.

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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.

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How to calculate Weighted average SAM or weighted average SMV ?

Whenever there is a need to find the average SAM, It becomes quite clear that simple average doesn’t give us the right picture. This is because simple average divides the SAM equally between all the styles. This division is wrong because there will be some styles with bigger order Quantity and some styles with lesser order quantity and the effect of order quantity will not be reflected in the averaged SAM. Therefore we need to calculate weighted average SAM whenever there is need to find average. Continue reading “How to calculate Weighted average SAM or weighted average SMV ?”

Deciding factors for number of garments on a marker

Fabric consumption depends greatly on the number of garments on a marker because the more the number of garment patterns on a marker the better is the marker efficiency. So a 6 way marker will have better marker efficiency than a 4 way marker which means that fabric consumption will be lesser for higher way markers. Therefore, standardizing the number of ways is very important because only then we will be able to control the fabric consumption. Continue reading “Deciding factors for number of garments on a marker”