Online Sweater Study

Best Individual Incentive Scheme For a Manufacturing Industry

noreply@blogger.com (Md. Salim Reza) — Fri, 18 Mar 2022 10:08:00 +0000

Individual Incentive:

Everyone always moves from one place to another for earning money. People wants to earn more to maintain improve life and for the future naturally. If there is any opportunity for earning more money like more salary, more production / incentive bonus etc, undoubtedly operators will jump for it. So need to design a lucrative incentive scheme and it will drive the people to work hard. And company will get more production with the same working hour. Incentive is the best motivator to increase performance.

Incentive Scheme: Part # 1

There are two types of incentive scheme mostly used in sweater industry that is -

Individual Incentive Scheme
Group Incentive Scheme.

Now questions is which operator and operations we should consider under this Individual Scheme. Operator / operations - should consider under this scheme those have direct impact on line output.

For example -

At Linking Section: Linkers, Trimmers

At Finishing Section: Ironers, Sewing Operators

And others all will consider under Group Incentive Scheme.

I will share here most used attractive individual incentive scheme. That will be benefited for both operators and company.

1. Individual Incentive Scheme:

The name define itself that incentive bonus will pay to those operator who are producing more than the target. Peoples will get incentive based on their individual performance. The more an operator achieve than the target, can avail more incentive. If not achieve more than the target, he / she will not eligible for any incentive. And this is the most popular incentive scheme for the operators who are rewarded individually for their additional contribution / performance.

For example,

Operational SMV = 0.9

Incentive will be pay per minute = 0.8 BDT

So amount per extra pcs = (SMV * 0.8) = (0.9*0.8) = 0.72 BDT

Target @ 100% efficiency = 66.67 Pcs

Minimum target @ 70% = 46.67

So those are achieving more than 46.67 pcs hourly will eligible for incentive as below,

Suppose operator A achieve 667 pcs at 100% efficiency end of the day at 10 hours. So he produces (667 - 466.7) = 200.3 pcs extra and will get incentive = (200.3*0.72) = 144.2 BDT.

We can calculate same things with per efficiency achievement like below,

Here, Incentive per Efficiency = (0.8*60) = 0.48 taka hourly and 4.80 taka per day at 10 hours.

From above data-

Operator A achieve (100% - 70 %) = 30% more efficiency than the target.

So he will get incentive = (30*4.80) = 144 BDT

Here is the example in brief,

Set a standard criteria to make it functional. Production recording system must be more authentic and reliable because payment will for every extra pieces/ extra efficiency achievement here.

Incentive Criteria:

Up to 69% efficiency - operator will not get any incentive
From 70% efficiency will eligible for incentive ( extra pcs or extra efficiency )
And max limit is 100 to 130% ( Based on management decision )
This is an individual incentive scheme
Payable incentive amounts will calculate daily basis
Payment will done as per the management decision which can be weekly, biweekly or monthly.

Advantages of Individual Incentive:

Operators work hard here with self-motivation to earn maximum amount of incentive
Incentive system drive the operators to work hard
So that produce quantity also increase
Labor productivity will increase
Will Increase job satisfaction through extra earnings
Labor turnover & absenteeism will decrease
Delivery lead time will decrease as well.

Disadvantage of Individual Incentive:

Some operators will get less incentive because of their low efficiency
Don't want to learn new process / skills if takes more time to learn
Team bonding may poor
Line may imbalanced due to some of the operators higher capacity and it may create bottle neck in line
Sometimes wrong incentive amount may be pay in case of unrealistic production data.

Conclusion:

Minimum and maximum target level may vary factory wise as per management decision. Minimum targeted efficiency level is 55% to 70% and maximum target level is 130%. So operators always try to make their time productive, even in their break time also for earning more money.

How to Motivate Garments Worker in a Production Floor?

noreply@blogger.com (Unknown) — Thu, 03 Mar 2022 15:37:00 +0000

How to motivate Garments worker?

Production with good quality and expected efficiency is the main demand of every manufacturing unit. Increasing productivity is must needed things to make a business profitable now a days. There are many ways to improve productivity and one of the best way to maximize productivity is motivation. A highly motivated operators can perform their job effectively than the less motivated operators. Most importantly they make a habit of doing work hardly. Motivated operators are more quality oriented and productive by following a best method to do the job.

There are many ways to motivate the people.

Money is the topmost effective motivator that can encourage the people towards work but it's not the only factors.

How to motivate Garments worker

Every people is different and the way of motivating them may also different. Here are some motivational tips to motivate garments worker.

Create a Positive Working Environment:

People will work more comfortably with happiness when they get a positive working environment. When people are happy to work then they became -

More punctual
Keep good inter-personal relationship
More productive
And efficient.

Encourage teamwork:

Teamwork is must needed for a company's success. The results are far superior to that of a person working alone. Advantages of effective teamwork like below -

Build strong relationship
Increase productivity
Delighted team member
Less absentiesm
Share the workload equally
Met the customer deadline

Provide lucrative attendence bonus:

Sometimes it can't possible to balance equal capacity with the absentees. So that production will hampared if absentiesm is more. To reduce absentiesm, can provide lucrative attendence bonus to them.

Performance bonus / incentive:

Each and everyone wants to earn extra money to maintain his / her family very well and for the future savings also. So when there is an opportunity to earn extra money, people will drive to get it. Here extra earnings opportunities will force them to work hard willingly. Money is the motivator here and it will increase individual productivity and production pieces with the same available resources. There are two types of incentive scheme are running presently at production floor (Fixed Salaried).

1. Individual Incentive Scheme

2. Group Incentive Scheme

Offer consistent rewards:

Offering rewards for the best performance is also motivate the people to work hard consistently. It may very small things or very less expensive gift but has a great value to the associate when they receive it from the management. Rewards criteria can be design like below,

Category	Rewards Frequency
Best Operator of a Line	Weekly / Monthly
Best Operator of a section / Floor	Monthly / Yearly
Best Supervisor / Staff of a section / Floor	Monthly / Yearly

This recognition rewards increase the moral and create positive attitudes on workplace. Appreciating someone for his/her good job makes them feel good and encourages them to do good things continuously that improve their productivity.

Give the credit frequently to team member:

Peoples need to know their values at work and it will motivate them to work on regular basis. Don't forget to thanks your team members end of the day for achieving target or complete a special work within the time.

Think about employees quality of life:

Good HR policy also motivate the people to put more effort on work to achieve the best results for the company. For example-

Pay salary within the commited date
Provide insurance facility, service benefit and provident fund for less turnover
Check & allow leave when they really need it
Celebrate special days in the factory premises
Create an opportunity to buy daily needs products from factory premises with lower cost.

Conclusion:

The objective of motivation is to enhance productivity by the operators willingly. But it is very important to understand what motivates them on workplace. Follow those things as regular practice to get the result always.

How to Find Actual Sewing Time By Using Machine RPM?

noreply@blogger.com (Unknown) — Thu, 27 Jan 2022 07:26:00 +0000

Benefits of Calculating Sewing Machine RPM

RPM stands for Revolution Per Minute. It refers to the speed of an electric motor which drives a machine to run. When an operator use standard RPM of a machine then he/she can produce standard pieces also. But produce quantity may vary than the target if he/she use more or less RPM level than the standard. Read in details How to Calculate RPM of a Sewing Machine? We will discuss Benefits of Calculating Sewing Machine RPM in this article.

Benefits of Calculating Sewing Machine RPM

Find actual sewing time / cycle time: By using actual used RPM of a machine, we can get actual sewing time / cycle time of an operation. To get this data, we need Loop / Seam length, Stitch Per CM and Used RPM of a machine. Now put those value to the equation and get actual cycle time. The equation of

Sewing / Cycle time = ( Loop Length Χ SPC Χ 60 ) / Used RPM

For example,

If a single needle sewing machine operator used machine RPM = 3000. How much time he has taken to sew a operation of 250 CM seam length where stitch per cm is 4?

So Sewing / Cycle time = ( 250 Χ 4 Χ 60 ) / 3000

= 20 Seconds

Cycle time variations and impact on production: Used less RPM of a machine means taking more times to complete that operation. So that production also goes down.

For example, used RPM is 2700 where others all data remain same.

Now Sewing / Cycle time = ( 250 Χ 4 Χ 60 ) / 2700

= 22.22 Seconds

On the other hand, use more RPM reduce cycle time and it means produce more quantity.

For example, used RPM is 3600 where others all data remain same.

Now Sewing / Cycle time = ( 250 Χ 4 Χ 60 ) / 3600

= 16.67 Seconds

By measuring cycle time through used RPM we can determined how much we need to improve and where to improve to get right production.

Find Sewing Time by Used RPM

From above table, we can say increasing machine RPM always reduce sewing time of an operation and thus we can improve production / productivity by increasing machine RPM. But machine should be set properly by the machine technician to maintain standard process quality.

How to calculate RPM of a Sewing Machine?

noreply@blogger.com (Unknown) — Thu, 20 Jan 2022 11:15:00 +0000

What is RPM?

RPM stands for Revolution Per Minute. That means speed of rotation of a machine per minute is RPM. Every sewing machines have maximum RPM level / speed limit and it has written on the motor. Production will also be higher when an operator operate a machine at high RPM. But sewing operators can't perform a task by operating a machine at maximum RPM because of operator skill level, process difficulties, process Quality & machine quality.

Now we will know how to calculate sewing machine RPM?

Calculation RPM of a sewing machine

We can find sewing machine RPM in 3 ways such as-

From user manual of a machine or Sticker attach on a motor: We can find maximum RPM of a machine from here. That means what is the maximum speed level, a machine can be performed we may know from that user manual / sticker.
By using laser Tachometer: Measuring speed level of a machine, Laser Tachometer is a very useful tools. By using laser Tachometer, we can observe average or maximum speed of a machine. Read in details How to Use Laser Tachometer from www.onlineclothingstudy.com
Calculating actual RPM of a machine while performing by an operator from physical data: How much speed an operator use while operating the machine, we can measure by using following equations-

Machine RPM = ( Loop Length Χ SPC Χ 60 ) / Cycle Time

Here to calculate machine RPM, need following physical data.

- Make a loop & mark straight on the loop to stitch.

- Set the machine SPC ( Stitch Per Centimeter = 4 )

- Put thread on needle & bobbin

- Use flat pressure foot

- Run the machine at maximum speed following mark

- Record the cycle time of stitching ( for example 15 seconds )

- Measure the stitch / seam length of the loop for example 250 centimeter.

Now use all the value to the equation and get machine RPM.

Machine RPM = (250*4*60)/15

= 4000 RPM

Those are the ways we can calculate sewing machine RPM.

By using same equation, we can calculate operator's using machine speed / RPM also.

For example, 20 seconds time it takes to complete a cycle where all other data is remain same then,

Used Machine RPM = ( 250*4*60)/20 = 3000 RPM.

Note: If a sewing operator operate a machine with lower RPM level, then production will come less than the target. So by improving / increasing used RPM level, we can increase productivity as well. Learn more about Improve Productivity in 20 Ways.

Importance of Quality Control in Manufacturing Industry

noreply@blogger.com (Unknown) — Thu, 13 Jan 2022 09:56:00 +0000

Quality:

Level of acceptance of a products or services is called quality. Quality has to maintain from the initial stage of sourcing raw materials to finished goods to sell those product to end user through buyer / retailer. A quality garments should be free from all kinds of defects cause no one will buy a product with poor quality and visible defective garments. There is no alternative ways of producing quality product at all. Read in details about different types of defects found in a production floor.

In this article Importance of Quality Control in Manufacturing Industry will discuss today.

Achievieng customer satisfaction is the ultimate goal of every manufacturing company. Quality of product is the main focusing point to be satisfied. To produce good quality product, there must need a persistent effort from every responsible person.

What will happen if not produce quality products?

Alteration & rejection of garments will be high.
Additional manpower need to provide for check.
Waste Productive time for alter rectify.
Production will be less as can't use 100% working hour of all manpower.
Style closing delay.
Work extra hours to recover it.
Inspection may fail and so that recheck process need to conduct for resure quality.
Delivery will not on time, Short shipment may happen.
Production cost will increase / Less profit.
Customers may unhappy so that factory may loose brand value.

There will be more financial loss if garments got rejected / Claimed after shipment also because of critical mistakes ( quality failure ) like style mistake, color mistake, wrong size ratio and shade variation.

This is why it is important to control and maintain quality while producing goods from the beginning to end of all processes. It's not possible to produce 100% fault free goods. So to ensure the quality products, check system must be running in every process of every section and every checkers, operators, inspectors, supervisors has to take ownership to continue. If the problem find out by the checker on initial stage then corrective action can be taken to solve.

There are 3 main stage of check / inspections involve for the production cycle. Those are-

Inspect Raw Materials - Fabric, Yarn and all kinds of accessories.
In process - Inline check/ Roving QC, Endline Check at every line of every section and pre-final inspection before ready for final inspection.
Final Inspection.

So it is must needed quality control system in right places to monitor & ensure quality product for the reputation and growth of a company.

Please remember-

Quality Is Not An Act, It Is A Habit.

Read about Sweater Manufacturing Process A to Z – Flow Chart to see the checkpoints details.

3 Garments Production Tactics That Will Help You to Win

noreply@blogger.com (Unknown) — Mon, 10 Jan 2022 08:46:00 +0000

Production is defined as output quantity get from utilization of all resources within the time period. Production is the most important element in the contest of manufacturing sector at present. Produce more production to earn more profit. All efforts may be gone in vain if the output quantities are not meet satisfactory level what you plan to get from the production line.

We can calculate production per day from a specific line or a unit by following formula,

Production Per Day = No of Machines X Produce qty by Operator per Hour X Total Working Hour

From the above equation we can say- 3 factors are directly involve for the production. Here if one factors is increase then total production will be increase. Those are -

No of Machines / Manpower
Unit produce by Operator per Hour
Working Hour in a Day

For Example, A production floor have 260 machines to work and Shift working hours 10 in a day. If each operator avg capacity of producing 4.5 pieces per hour then total production quantity end of the day will be -

Production Quantity = 260 X 4.5 X 10

= 11700 Pieces per day.

Now we will see how to increase production by improving those 3 factors.

1st Factor: No of Machines / Manpower

By adding some machines with the present capacity then daily production will be increase.

For example if machine quantity increased from 260 to 286 then total production will be,

Production Quantity = 286 X 4.5 X 10

= 12870 Pieces per day.

1170 Pieces production increase by adding 26 machines here.

2nd Factor: Unit produce by Operator per Hour

By improving operators production capacity / productivity, daily garments production can be increase.

For example if operators production capacity increased from 4.5 to 5 pieces per hour then total production will be,

Production Quantity = 260 X 5 X 10

= 13000 Pieces per day.

1300 Pieces production increase by improving productivity here. Productivity can be improved through training, motivation, use of technology advanced machines and IE method & tools.

Read in details Improve Productivity in 20 Ways .

3rd Factor: Shift Working Hour

Daily garments production can be increased by increasing total working hours daily.

For example total shift will work 11 hours instead of 10 hours then total production will be,

Production Quantity = 260 X 4.5 X 11

= 12870 Pieces per day.

Total 1170 Pieces production increased than earlier by increasing 1 hour Overtime here.

Table: Improve Production

How to Reduce Cost per Minute (CPM) in a factory

noreply@blogger.com (Unknown) — Thu, 30 Dec 2021 08:42:00 +0000

What is CPM:

CPM Means total cost incurred per minute for a production line, a section and full floor. CPM stands for Cost Per Minute.

We have learned how to calculate CPM in details earlier. How to reduce cost per minute will discuss today. Before learning reduction method, read first how to calculate it.

The equation to calculate CPM is -

CPM = Total Actual Salary of a Day of a line/( Total garments produced of that day Х Garments SMV )

There are three parameters required to find CPM. Among those product SMV and Total Actual Salary of a Day will remain same. So to reduce the CPM, need to increase-

· The production within the planned working hour.

· Achieve efficiency more than plan

For example, 32 manpower produced 600 pcs garments in a day with 75% efficiency. SMV of that garments is 20.98 min. If Total one day salary of that production line is 14700 TK then,

CPM = 14700/( 600 Х 20.98 )

= 1.17 Taka

But if that line produce 680 pcs garments at 85% efficiency then definitely CPM will be reduce. When garments SMV is 20.98 and Paid salary is 14700 tk then ,

CPM = 14700/( 680 Х 20.98 )

= 1.03 Taka

Comparison of Both Example:

How to Reduce CPM

From the above example, we can say by increasing production 80 pcs and efficiency from 75% to 85%, we can reduce cost per minute from 1.17 Taka to 1.03 Taka. That means 0.14 Taka cost reduced per standerd minute here. Read how to Improve Productivity in 20 Ways to increase efficiency.

What is CPM? How to Calculate Cost Per Minute In A Production Line?

noreply@blogger.com (Unknown) — Wed, 29 Dec 2021 07:04:00 +0000

What is CPM:

CPM is Cost per minute. That means CPM of a line is the cost incurred per standerd minute for that production line.

How to Calculate Cost Per Minute

There are two types we can calculate cost per minute of a sewing line. Those are,

Estimated cost per minute
Actual cost per minute

By those method, we can measure cost per minute of a-

Production line
Specific section
A production floor
Full factory

1. Calculate Estimated cost per minute of a line.

To calculate estimated CPM of a production line, we need below information correctly,

Total one day salary of that line
Total Minutes available to work on that day
Line Efficiency of that line

Here,

To calculate total salary of a line consider all direct operators who are directly invovle with the production only like all operators, helpers, quality checkers. You can also include line supervisor and line QA if they are not considered under factory overhead cost.

Total Minutes available to work on that day = (Number of total workers Х working hour Х 60)

And Line Efficiency of that line for example 75% ( It may vary factory to factory )

Now equation to calculate estimated CPM is given below,

Estimated CPM = Total Salary of a Day of a line/( Total Available Minutes Х Line Efficiency )

For example, Total one day salary of a production line is 14700 TK where total 32 manpower ( 28 direct operators ) involve for the production for 10 hours and line efficiency is 75%.

So, Cost Per Minute = 14700/( 32 Х 10 Х 60 Х 75%)

= 1.02 Taka

2. Calculate Actual cost per minute of a line.

To calculate actual CPM of a production line, we need below information,

Total one day salary of that line
Total garments produced of that day
Garments SMV

The equation to calculate actual CPM of a line is -

Actual CPM = Total Actual Salary of a Day of a line/( Total garments produced of that day Х Garments SMV )

For example, Total one day salary of that production line is 14700 TK where total garments produced of that day is 600 pcs and garments SMV is 20.98 min.

So, Cost Per Minute = 14700/( 600 Х 20.98 )

= 1.17 Taka

Organogram of Industrial Engineering department in a Manufacturing Unit

noreply@blogger.com (Unknown) — Thu, 23 Dec 2021 13:09:00 +0000

Department of Industrial Engineering:

Industrial Engineers team plays a vital role in the garments industry. There are many challenges in garments manufacturing like incresing labor/overhead cost & lead time goes shorter day by day. IE dept. works all of these challanges to mange it through IE techniques & applications. Garments factories learn how to save time, increase productivity, meet daily production target and evaluate hidden opportunities in the production areas through the acceptance of Industrial Engineering. This department always move to improve current system / method to a best one and maximize the efficiency to ensure maximum output. Click here to know Why I should build-up my carrier in sweater industry as IE .

Organogram of Industrial Engineering department:

Organogram of IE Dept. may vary based on factory size and capacity. In general IE and Planning dept are performing as a individual dept and both dept are combined in some factories also as per management decision.

Head of IE ( GM / AGM / Sr. Manager ) are there for multiple units or group of companies.

Organogram: Department of IE

IE people works in every section of manufacturing unit like cutting, sewing, finishing, packing in garments and knitting to packing in sweater industry. So, without having IE department surely a company team is incomplete.

What is line Planning? Benifits of line planning.

noreply@blogger.com (Unknown) — Mon, 20 Dec 2021 12:35:00 +0000

Line Planning:

A line plan is a roadmap used for allocation of orders to the line according to delivery lead time. Line loading plan is an important task for every planner.

There have a quote about planning by Dale Carnegie,

An hour of planning can save your 10 hours of doing.

From a proper line loading plan, one can get following information,

Start & completion date of an order.
Number of allocated line for the order
Target of each line to be achieve to meet delivery
Required days to complete that order
Which style comes next and start date.

By those information, floor responsible person can take preparation on that. Like below,

Benifits of line planning:

Responsible IE can take preparation like keep ready layout, discussed with production & maintenance team for smooth feeding.
Responsible production people can take necessary preparation like operator selecting, critical operation analysis with IE for next upcoming feeding.
Maintenance dept. can arrange required machines based on requirement and set special machine earlier if need.
Like that all other production related dept. take proper action to execute the plan on floor for smooth production and delivery as well.

After published the proper plan, everyone must need to follow it to execute on floor. Progress need to observed regularly and recorded properly so that the data can be analyzed to take initiative in case of any deviation from the plan. If plan fail, it will directly impact on delivery. So corrective action should take immediately for example change the plan in case of any deviation from the plan to secure delivery.

Notes:

Plan should be very simple and easy to understand with a strong reporting system so that right information reaches at right place in right time. Because always have a plan, and belive in it. Nothing happens by accident.

Define Takt Time. Use of Takt Time in Apperal Industry.

noreply@blogger.com (Unknown) — Mon, 13 Dec 2021 14:37:00 +0000

Takt Time:

Total allowable time to produce a product from customer is called Takt Time.

Purpose of takt time is to match pace of production exactly with customer demand to ensuring shipment on time. So, in general - Takt time is the minimum required pace of production based on delivery demand of customer.

How to measure Takt Time?

Formula of measuring Takt Time like below:

Takt Time = Net Available Time ➗ Customer Demand in Pieces

Two things are required to measure Takt Time those are-

Net Available Time
Customer Demand

Here is Net Available Time is total productive time in a day per shift excluding break time.

And Customer Demand is total required pieces in a day to meet delivery as of customer/buyer demand.

For example,

A production line runs 10 hours with 20 operators and 800 pieces required to produce within this time as of customer requirement.

Here net available time = 20*10*60 = 12000 Min & Customer Demand = 800 Pieces.

So, Takt Time = (12000 ➗ 800) Min

= 15 min per pieces.

And per operator Takt Time = (10*60) ➗ 800

= 0.75 Min per pieces // 45 Seconds (0 .75*60)

Use of Takt Time in Apperal Industry.

From above example, Takt Time is 0.75 min per pieces per operator and total 15 min for that line to produce a garments. If per pcs garments can be produce within this time then smoothly possible to meet customers delivery deadline and delivery will be on time. But if the producing time is greater than 0.75 min then total pcs cannot produce within the time period. In this case, factory going for extra hour to cover that quantity for OTD.

For balancing a production line, Takt Time is taken as a base to distribute all the work to every operators equally. That means Takt Time is 0.75 min means each & every operations need to distribute to the all operators very close to the Takt Time ( 0.75 Min ) to create a more balanced line. That means to equalise workload, each operator will get work of about 45 seconds of work.

How to get required manpower by using Takt Time?

Say for example - Garments SMV is 15 Min = 900 Seconds. So to produce a piece in 45 seconds, the total number of operator required 900/45 = 20 Operator if everyone work at 100% effiiciency.

That means all operations need to distribute within 20 operators equally.

Important Notes to Remember:

Is takt time and cycle time are same?

Simply no. Takt time is NOT same as cycle time. Cycle Time is the time duration from the starting point of a task to starting point of next task. On the other hand Takt Time is the time allowed to produce a product from buyer / customer.

Takt Time can't be measure by stopwatch.
Takt Time may increase/decrease by increasing / decreasing available time & customer demand.

How Many Lines Required To Complete an Order of 30000 Pieces?

noreply@blogger.com (Unknown) — Tue, 30 Nov 2021 13:22:00 +0000

How to Calculate Required Lines to Complete the Order within the time frame?

Each and every people of any manufacturing unit is working for on time delivery.

To calculate required lines we need following information accordingly...

Order qty with extra knit/cut
Inhand days for production
Working hour in a day
Garments SMV
Number of installed machine / Manpower per line
Targetted line efficiency

Here the equation is,

Required Line = Order Qty*SMV /(Number of Manpower*Working Hour*60*Days Inhand*Eff.%)

Or,

Required Line = Order Qty/(Number of Manpower*Working Hour*60*Days Inhand*Eff.%/SMV)

For Example,

Order Qty = 30000 Pcs.

Manpower Per Line = 22

Working Hour = 10

Efficiency = 70%

SMV = 13.54

Days Inhand for Production = 11 Days

So, Required Line = (30000*13.54)/(22*10*60*11*70%)

= 406200/101640

= 3.996

= 4 Lines

Here the answer is : 4 lines required to complete an order of 30000 pieces.

Here is in brief,

Step 1: Calculate Per day Required pieces.

Daily production requirement in pieces = Order Quantity / Inhand days for production

= 30000 / 11 days

= 2727 Pieces

Step 2: Calculate production capacity of each line.

Capacity =( Number of Manpower*Working Hour*60*Eff.%) / Garments SMV

= (22*10*60*70%) / 13.54

= 682 Pieces Per Line .

Step 3: Calculate required line to complete that order within the time.

Required Line = Daily production requirement / Per line capacity

= 2727 / 682

= 4 Lines.

This is how we can find how many lines need to run to complete an order within the production lead time. Learning curve need to consider for new setting line here.

How To Calculate Average SMV Of a Factory While Produce Different Style Last Month?

noreply@blogger.com (Unknown) — Mon, 08 Nov 2021 15:09:00 +0000

How To Calculate Average SMV For Multiple Style?

What is SMV:

SMV means total time required to complete a garments. If a garments SMV is 15 that means the time duration from starting of first process to end of last process will 15 min and will produce a complete garments within this certain period. SMV is used for setting individual operator target & line target. Read more details about What is Cycle Time, Basic Time & SMV?

Calculating Average SMV of a Factory

We will know today how to calculate average SMV while producing different styles with different product SMV. There are some ways to determine average SMV will discuss below:

Suppose total 5 styles run in a production floor last month.

Style SMV Production Style Ratio

A 11.25 75000 30%

B 16.15 75000 30%

C 20 37500 15%

D 24 37500 15%

E 32 25000 10%

Method 1:

Average SMV of all 5 style = Sum of all SMV / Number of Style

= (11.25+16.15+20+24+32)/5

= 103.4/5

= 20.68 Min

But this is wrong way of calculating average SMV. You will get wrong figure if you use this average SMV.

Correct Method 1:

SAH of Style A = Production * SMV/60

= ( 75000*11.25/60)

=14062.5 Hour

Same way Style B = 20187.5 Hour, C = 12500 Hour, D = 15000 Hour & E = 13333.33 Hour

Total SAH = 14062.5+20187.5+12500+15000+13333.33 = 75083.33 Hour

And Total Production = 75000+75000+37500+37500+25000 = 250000Pcs

So SMV = (Sum of SAH*60)/Total Production

= (75083.33*60)/250000

= 18.02 Min

Note: As SMV also in a minute so, we can use below equation also.

Average SMV = (Style A SMV * Output)+(Style B SMV * Output)+(Style C SMV * Output)+(Style D SMV *Output)+(Style E SMV * Output)/Total Production

Correct Method 2:

Average SMV = (Style A SMV * Output %)+(Style B SMV * Output %)+(Style C SMV * Output %)+(Style D SMV * Output %)+(Style E SMV * Output %)

=(11.25*30%)+(16.15*30%)+(20*15%)+(24*15%)+(32*10%)

=3.375+4.845+3+3.6+3.2

= 18.02 Min

By calculating average SMV, we can estimate total factory production capacity.

If you have any confusion/questions regarding this , please feel free share your query with us.

What is Man to Machine Ratio and How to Measure Man to Machine Ratio In Garments Industry?

noreply@blogger.com (Unknown) — Tue, 26 Oct 2021 15:04:00 +0000

Man to Machine Ratio:

The total number of workforce in a factory for the total number of operational machine is defined as man to machine ratio. That means Man to Machine Ratio is the ratio between total workforce and the total number of machines.

Benifits of measuring MMR Ratio:

By measuring MMR ratio, factory management can assess how many employees has recruited per machine. And this ratio gives a clear idea about indirect labor cost of a factory.

Measuring Man To Machine Ratio

How to calculate MMR Ratio:

We need following data to calculate man to machine ratio of a factory.

Total how many employees are there including indirect employees
Number of machines are there

For Example:

Total manpower of a factory is 1550 and direct operator is 850 among them. If total available machine is 700 then,

Man:Machine = 1550:700

= 2.21:1

And for the total direct operator,

Man:Machine = 850:700

= 1.21:1

MMR value is more means number of indirect employee is more. MMR value may different based on factory size and capacity.

How to Calculate Production Capacity of a Factory ?

noreply@blogger.com (Unknown) — Sun, 24 Oct 2021 14:46:00 +0000

Production Capacity of a Factory

Maximum potential output by using all current resourcees of a production floor is treated as Production Capacity of that floor. It is very important criteria to select vendor by the buyers based on production capacity to get their product on time. So it is very important to know factory capacity for Planning, Merketing & Merchandising dept. to book the order. Production capacity mainly depends on machine availability of a factory.

Calculate Production Capacity of a Production Floor

To calculate production capacity in pices of a factory in a day, we need following data,

Factory capacity in hours ( Input Hours )

For calculating factory capacity in hours, we need total available machines and working hour in a day.

For example,

Total machines of the factory = 260

And working hour per day = 10 hour

So,Total factory capacity in hours = 260*10 = 2600 hours.

Average product SMV

If only one style will run then need only that style smv to calculate factory capacity. And for multiple style with different product category, we need average SMV of all styles.

Say for example, average SMV is = 12.15

Average Efficiency

Take average achieved efficiency to calculate factory capacity in pieces. Say for example, factory efficiency is = 70%

Read more to learn : How to calculate factory efficiency?

Calculation of factory production capacity ( in pieces ) considering above data like below,

Production Capacity In Pieces = (Capacity in Hours*60/Avg SMV)* Avg Efficiency of a Factory

Production Capacity In Pieces = (2600*60/12.15)*70%

= 8988 Pieces in a day.

That is daily average production capacity of that factory. Now if we wants to calculate month total capacity of that factory then we need number of working days and multiple it with day days capacity.

If we consider 26 working days in a month then,

Monthly Capacity = Daily Capacity * No of Working Days in a Month

= 8988 * 26

=233688 pieces.

How Many Days Required To Complete an Order Of 45000 Pieces?

noreply@blogger.com (Unknown) — Sat, 23 Oct 2021 13:33:00 +0000

How to Calculate Required Days?

Planning dept make monthly line loading plan normally in advance so that all other dept can take preparation to allign with the plan. It is very important to know how many days required to complete an order. Planning and production dept has to follow it very closely to take deceision and make conscius of every responsible regarding on time delivery. Here is the equation with example to calculate required days to complete an order.

How many days required to complete an order?

We need following information to calculate it:

Order Quantity
Number of Manpower (Budgeted considering absentiesm 5%)
Number of line
Working Hour in a Day
Product SMV
Line Efficiency including Learning Curve Efficiency

First Example:

For Example,

Order quantity 45900 pieces with 2% extra
20 manpower per line & 4 line will perform this style
Working hours 10 per day
Product SMV 11.54
Efficiency level 40 % on day 1, 60% on day 2 and 75% on day 3rd onwards. ( Lurning cureve may vary based on product catagory)

So as we calculate required days from the beginning of that style, we need to consider learning curve period for each line. And if we calculate remain number of days for running style of remain qty then only consider pick efficiency.

Target calculation formula = (Manpower*working hour *60*targeted efficiency)/SMV

Now capacity at day1 = (80*10*60*40%)/11.54

=1664 Pieces

Capacity on 2nd day = (80*10*60*60%)/11.54

=2496 Pieces

Capacity on 3rd day onwards = (80*10*60*75%)/11.54

=3120 Pieces

Upto 3days total produce qty = (1664+2496+3120) = 7280 Pcs

Balance to complete from order qty = (45900-7280) = 38620 Pcs

Now days required for remain quantities = 37720 /3120) = 12.38 days.

So total days required to complete this order

= 12.38 + 3 = 15.38 Days ( Here 3 is Learning Curve Days)

16 days required to complete that order and on the last day need 7 hours only.

Calculation of Line Plan

Second Example:

"There have a shortcut ways to calculate it like below,

Required SAH = (45900*11.54)/60

=8828 Hour

Available Input Hours Per Day = 20*4*10

= 800 Hour

If factory run at 75% efficiency then,

Days Required to produce 45900 pcs = 8828/(800*75%)

= 14.71 days

14.71 days means 15 days required to complete without considering learning curve from 4 line and for considering learning curve add 1 more days here or follow first example.

Style Closing Report And Its Importance For Manufacturing Unit

noreply@blogger.com (Unknown) — Tue, 19 Oct 2021 14:20:00 +0000

Style Closing Report / Order Closing Report / Leftover Garments Closing Report

Managing production floor, we need to follow-up everything daily. And to follow-up accurately , we need report for specific purposes. There are various kinds of report are maintaining responsible department in regular basis like Manpower Report, Daily Forecast Report, Production Report, Efficiency Report, Lost Time Report, Weekly Plan, Monthly Plan ,Plan Vs Achievement Report , Style Closing Report etc. To understand how a factory is performing, we need those report for further analysis to improvement.

Style closing report is one of those report in everythat is prepared and analyzed by planning and production concern manufacturing industry. In this report, I will explain importance of closing report and how to make it?

To ship actual order quantity 100% every manufacturer knit 101 to 103% based on product category and wash type because of damage issue which one we can't rectify.

Benefit of Order Closing Report:

1. Observe Knit / Cut to Ship Percent: To ensure maximum quantity delivery, factory management are following knit to ship percent for every order. Because excess quantity not shipped means create wastage for a manufacturing unit.

Use following formula to calculate Knit to ship %.

Knit to ship % = (Total Shipped Quantity / Total Knitted Quantity)*100

= (9980/10120)*100

= 98.6% ( here 1.4% short ship than the knitted quantity).

2. Observe Order to Ship Percent: Every factory wants to ship at least 100% of order quantity and try to ship extra. Because short ship is negative effect for any factory to customer and directly impact on factory profit.

Use following formula to calculate Order to ship %.

Order to Ship % = (Total Shipped Quantity / Total Order Quantity)*100

= (9980/10000)*100
= 99.8%

3. Traceability of Knitted Quantity: Ensure no missing garments regarding the order. For Example, In style A order quantity 10000 pieces and Knitting quantity 10120 pieces. So here knitted quantity is 120 pieces ( 1.2% extra). If ship quantity is 9980 pcs then it will 20 pieces short from the order quantity and 140 pieces short from the knitted quantity. That 140 pcs garments should be on the floor and to understand why those garments can't ship.

4. Section Wise Damage Status: If those garments are damage then findout what kinds of damages are there.

5. Fulfill Customer Requirements: Some customer don't like to see their garments on local market because of brand value. So after delivery close, an audit conduct by the customer to see those excess garments physically. By maintaining closing report and kept those garments separately, a factory can fulfill their requirement.

Here is a template of closing report.

Template Of Order Closing Report

Shipment is the ultimate goal of every department related to production.

Difference between Production and Productivity in a Manufacturing Unit

noreply@blogger.com (Unknown) — Sat, 16 Oct 2021 15:25:00 +0000

Production:

Production is a complete process to transform raw material input into an output with required quality. The sum of produce quantity of a line is treated as production end of the day of that line. Suppose line A produce 660 pcs in 10 hours shift with 20 manpower. So that line supervisor will report to management or his superior, production is 660 pieces. No need others data like how many labor/machine, working hour, achieve efficiency level get involve there to produce that much quantity although all those things used there.

Productivity:

Productivity is the ratio of output and input. Productivity is measured to observe how effectively a company using their resources.

Productivity measuring formula = Output ÷ Input

Difference between Production and Productivity

From first example,

Here output = 660 pcs & input 20 manpower.

So, Labor Productivity = 660/20 = 33 Pieces.

By the same way we can measure machine productivity. To measure machine productivity, one need how many machines was involve producing that quantity?

Machine Productivity = Total Output ÷ Number of used machines

Production and productivity- both are important in a manufacturing unit and directly co-related with each other. When productivity will increase then production also will increase. Read how to improve productivity in an organization.

Difference between Productivity & Efficiency

noreply@blogger.com (Unknown) — Wed, 13 Oct 2021 13:41:00 +0000

Difference between Productivity & Efficiency:

Productivity:

The ratio between Output & input is called Productivity. Productivity is a very familiar word in any production based organization. Cost are going high day by day. To minimize manufacturing cost and make a company more profitable, increasing productivity is the best way. Productivity can be measured of Labor Productivity and Machine Productivity of a production line and whole factory as well. Productivity expressed in pieces. For labor productivity it will – Number of pieces produced per labor and for machine productivity it will – Number of pieces produced per machine. Learn more details about How to increase productivity.

Equation of measuring Productivity = Output ÷ Input

Efficiency:

Efficiency is the ratio of total produced minutes and total input/working minutes. Efficiency always expressed in percent. Efficiency is measured for Individual Operators, Production Line & Whole Factory Efficiency.

Equation of calculating Efficiency is as follows,

Efficiency = (Total Output Minutes ÷ Total Input Minutes)*100

Or, Efficiency = (Total Output Hours (SAH) ÷ Total Input Hours)*100

Difference Between Productivity And Efficiency

For Example no 1.

A line of 20 operators produced 800 pcs yesterday in 10 hours shift where product SMV is 11.25 , now calculate productivity & efficiency of that line to see the difference in results.

Labor Productivity = 800÷20 (Here Output is Produced quantity 800 pcs & input is 20 operator)

= 40 Pcs

Calculate Efficiency,

Total Output Hours (SAH) = (Output*SMV)÷60

= (800*11.25)÷60

=9000÷60

=150 Hour

And Input Hour = Manpower * Working Hour

=20*10

=200 Hour

So Efficiency = (Total Output Hours (SAH) ÷ Total Input Hours)*100

= (150÷200)*100

=75%

That is the main fact of Productivity in Pieces and Efficiency in percent. Both are important and use to understand individual, a line and factory performance.

To compare productivity with another line, it is very important fact is product category and SMV. With different SMV and manpower, comparing productivity will not figure out right things. Need same style and SMV while comparing productivity with others team and factory as well.

For better understand, here is the Example no 2,

A line of 18 operators produced 400 pcs yesterday in 10 hours shift where product SMV is 20.25 , now calculate productivity & efficiency of that line to see the difference in results.

Here, Labor Productivity = 400÷18

=22.22 Pcs

And Efficiency = (400*20.25*100)/ (18*10*60)

= 75%

Now if we compare both example, see different productivity 40 pieces in example no 1 and 22.22 pieces in example no 2 where efficiency is same 75% in both case. I think now clear about the differences between productivity and efficiency.

Difference Between Defect and Defective Product with Example. How to Measured those?

noreply@blogger.com (Unknown) — Tue, 12 Oct 2021 13:33:00 +0000

Defect:

When a product not meeting specific requirement of the customer is called defect. In other words, A defect is a parameter which decide a garments is passable or not. Lack of standard requirement of a product or services is treated as defect. Like Sleeve / back-front part up-down, Broken Stitch, Skip Stitch etc.

Defective:

Defects occurred in any pieces is called defective pieces. That means defective pieces/ any kinds of product are those item in which found at least one defect & quality checker keeps them separate from good pieces for further process. In a defective pieces, there may contain one or more defects. When defect and defective garments are very less means within the tolerance among the PO quantity is considered as good quality. But if defects / defective garments are high is considered as the bad quality. Achieving right quality is not only QA department responsibilities. Quality is everyone's responsibility.

Defective Garments

Quality checkers are recorded all those data regarding defect & defective pieces in a company provided sheet on hourly basis. Quality & production team will follow these report to solve the issues. For better follow-up, there are two measuring types are commonly used in factories.

DHU - Defect per Hundred Units
Defective %

Defect per Hundred Units (DHU):

Total number of defects found in 100 pieces checked. Formula to measure DHU is,

DHU = (Total number of defects found*100)/no of pieces checked

For Example, A quality checker has checked 80 pcs sweater / garments on first hour. He /she has found 10 pcs defects from 7 defective garments.

So, DHU = (10*100)/80

=12.5

Learn more details about How to Measure DHU in a Manufacturing Unit?

Calculating Defective %:

Total number of defective garments found in 100 pieces checked. For Example, Considering first data,

Defective % = (Total number of defective garments found*100)/no of pieces checked

= (7*100)/80

= 8.75% On First Hour

If a checker found 45 defective garments among 640 pcs inspected quantity then defective percent will be,

Defective % = (Total number of defective garments found in a day*100)/no of pieces checked

= ( 45*100)/640

= 7%

There is no alternative achieving quality. Because bad quality waste valuable productive time & wasting money. And right quality is the fact of company reputation and customer satisfaction.

What is DHU? How to Measure DHU In A Manufacturing Unit?

noreply@blogger.com (Unknown) — Sun, 10 Oct 2021 12:06:00 +0000

What is DHU? How to Measure DHU In A Manufacturing Unit?

In earlier post, we have learned different types of major defects of sweater factories. There is no alternative achieving quality of a product. So to maintain standard quality, set check post in different areas-

To detect defects at the source
Stooping defective garments passing to the next process
To find who are producing defects
Solve there instantly & get good quality products.

In general, check start in a sweater factories from raw materials stage (yarn stage) to packed garments to stop passing defective garments. Check points are like below,

Yarn quality
Knitted panel quality
Linking quality
Trims and Accessories quality
Finishing quality
Packing quality

What is DHU?

DHU stands for Defect Per Hundred Units. That means total number of defects found per hundred pieces check is called DHU. Also it is treated as DPHU ( Defect Per Hundred Units ).

From every checkpoints, quality checker detect defects & record them in a established sheet provided by the QA dept. In here, checker will record the total number of defects found in a day, total defective garments & total check quantities of that day.

Click to learn more about defect & defective garments.

How to Measure DHU In A Manufacturing Unit?

To measure DHU of any process/checkpoint, following information need those are recorded by quality checker.

Total number of defects
Total check quantity

Now we can calculate DHU by using following equation.

DHU = (Total defects found in a day * 100)/ Total inspected pieces

For example: A quality checker has checked 800 pcs sweater / garments in a day. He /she has found 135 pcs defects from 70 defective garments in a day , then what is the DHU of that process?

So DHU = (135*100)/800

=16.87

Template of Measuring DHU

Here is the Data capturing template to measure DHU on every check stations. Line Supervisor & QA of respective line will check this report hourly basis and take action immediately to solve the issues on source for producing best quality products.

Different types of major defects of sweater factories

noreply@blogger.com (Unknown) — Fri, 08 Oct 2021 10:19:00 +0000

What is Defect?

Failure of customer requirements to make a product is called defect. In other words, a lack of something that results in incompleteness of quality standard of a product is called defect.

No one like to produce defective garments but it is common problems for any manufacturing unit. So before sending goods to next section and before offering goods for final inspection, find & rectify all defects.

Every section of a production unit have check point where QC check from yarn stage to pack complete garments to ensure right quality of products. Because it's the fact of company reputation & customer satisfaction.

Classification of defects:

It is very important to understand different types of defect and source of the defects. We will discuss all about defects here category wise.

Defects are mainly in 3 categories those are,

1. Critical: Safety issue for a user/consumer & violate mandatory regulations of buyers is treated as Critical defects. It directly hit on company reputations & getting next order from buyers.

For Example:

2. Major: A defect that is reducing usability/sale ability of a product is treated as Major defects. It causes of bad reputation for a factory & less sales.

3. Minor: A defect that usually happens for the poor workmanship is treated as Minor defects. It's not hampering in sales but it causes of shorten life cycle of a product.

Linking Alter

Now here are most common defects are mentioned below.

Yarn & Knitting Defects:

Slabs
Naps
Yarn thick & thin
Spot on yarn
Uneven yarn dye
Barriness
Knot
Foreign Yarn
Needle drop
Puckering
Yarn Twist
Cut damage
Wrong placement of hole mark
Shading due to lot mistake

Linking:

Needle Drop

15. Brocken Stitch

16. Stitch Uneven

17. Stripe Up-down

18. Pull Yarn

19. Seam Wavy

20. Skip Stitch

21. Needle Mark

22. Machine Gap

23. Size mistake of panel while attaching

24. Wrong yarn use while stitching

25. Poor Trimming

26. Over Stitch

27. Shade - Bundle Mismatch

28. Oil Mark

Stitch Broken

29. Bartack Missing

30. Irregular SPI

Washing:

31. Hand Feel not match with the Approved Sample

32. Uneven Dyeing

33. Criss Mark

34. Shade Variation

35. Dyeing Spot

Finishing & Packing:

36. Label Placement Wrong

Stitch Wavy

37. Label Size Mistake

38. Wrong Care Label Attach ( Care Label Instruction Wrong).

39. Brocken Stitch After Wash

40. Shiny Mark

41. Measurement Up-down

42. Spot Label Attach

Stripe Up-down

43. Care/PO Label Missing

44. Wrong placement of Hole/Button

45. Button 1/2 Stitch

46. Label/ Button Color Fade Due to Re-wash

47. Irregular Stitch

48. Sleeve Up-down

49. Spare Button Missing

50. Price Tag Mistake with Another Style

51. Additional Tag not Use

52. Color Code Mistake of Care Label/ Price Tag

53. Use Broken Button

54. Sticker Placement Wrong

55. Wrong Assortment

56. Folding Measurement Wrong

57. Use wrong Carton Dimension / Use Another Style Carton

Those are the most common defects in a sweater manufacturing unit. Produce defect & rectify those is always kill valuable productive time and wasting money as well.

Sweater Manufacturing Process A to Z – Flow Chart

noreply@blogger.com (Unknown) — Tue, 05 Oct 2021 12:28:00 +0000

What is Sweater?

A piece of clothing made from wool, cotton, synthetic fibers or combinations of these is called sweater. Sweaters are made for adults and children (from new born baby to adult’s sizes).

Kinds of Sweater:

· Long/Short Sleeve Pullover

· Long/Short Sleeve Cardigan

· V-neck Sweater

· Crewneck Sweater

· Slipover/Sleeveless ( Vest )/Tank top Sweater

· Hoodie

· Mockneck

· Turtleneck

· 1/2 Zip and Full Zip Sweater Etc.

Sweater Manufacturing Process:

Sweater Manufacturing Process A to Z – Flow Chart

Sweater manufacturing process also similar to garments manufacturing process (from sample development to receiving an order) to make process simple. Others all the processes are discuss here.

1. Yarn Sourcing: Yarns are the main raw materials to make a sweater. Merchant dept. start sourcing of yarn after confirm an order based on customer requirement.

2. Winding: Normally yarn in-house in factory store from supplier in hanks / spool form. So need to winded into cones by using Winding machine. After winding, those cones will store in yarn distribution section to distribute for knitting production by keeping proper record.

3. Yarn Issue to Floor: Yarn distributor will collect it as per plan and distribute to the knitting operator. Yarn distributor will maintain proper document of yarn receiving and issuing data.

4. Start knitting In A Panel Form: Knitting operator knit panel by knitting machine and make bundle with 10 to 12 pcs for next process.

5. Panel Check: Check knitted panel 100% to find different types of faulty panel to rectify or replace those. Because faulty panel will kill valuable productive time in next section.

6. Stored in Panel Bank Area: A specific area to keep the color wise panel separately. Panel Distributor of Knitting have a vital role here maintaining panel issuing data by counting. Record customer, color and size wise quantity as per PO sheet.

7. Input to Linking Section: Linking distributor is responsible collecting panels from panel bank area and give input to linking line. One helpers also allocate with him to provide required knitting accessories to the linking operator. Recording data is a big role of linking distributor also to complete the order po wise.

8. Start Linking: All the knitting panels are attach together as per process layout by linking machine to give a complete look of sweater. Follow quality instructions as per approved sample to maintain customer requirements. In traditional sweater factories- linking operators complete all the process individually. But currently in some factories introduce process wise separate operators as per layout and get significant result in productivity.

9. Trimming/Mending: Trim all uncut/loose yarns & put tack on joint area as per quality requirements. Pull neck/ piping area to find in case of drop needle, open/broken seam & mark it by neck pulling operator. Mending operator will rectify those faulty areas.

10. Light Check: Check all seam areas of a complete sweater - side seam, shoulder & full back/front panel to find linking & knitting defects by light check machine.

11. Quality Check: Check all the areas to ensure overall quality as per approved sample.

12. Inspection by QA: Inline QA randomly check here to take necessary steps immediately in case of any quality failure.

13. Send to Wash: Another linking distributor will send quality pass garments to wash by physical counting and keep record.

14. Washing: This is very important to meet shrinkage label of sweater by washing. If there any wrong recipe used while washing, then it may not meet standard level of measurement or sweater's hand feel. Wash sweater following customer recommendation for cotton and acrylic based sweater.

15. Special Attachment: There have a separate areas for special attachment. If there any special attachment like zipper, back moon, elbow, neck tape etc then complete those process in separate areas.

16. Fin Input: Fin distributor will give input to line as per plan & keep proper record po wise.

17. Light Check: To find defects, do light checking again. Because after washing, there are possibilities in Broken stitch, Color bleeding, uneven dyeing etc.

18. Label Attach: Sewing operators attach necessary labels ( main label, care label, hanger loop etc).

19. Quality Check - PQC/FQC: Check inside & topside to find defects. Trim all uncut thread & loose yarn.

20. Ironing: Board cutter keep ready iron board size wise by following customer provided measurement sheet. Iron operators doing steam iron using iron board & steam iron machine.

21. Measurement Check: Measurement QC check those iron complete pieces 100% to ensure customer requirements.

22. Get-Up Check: Getup operator check all the attached accessories are as per approve sample & overall outlook.

23. Inspection by QA: Inline QA will check randomly to ensure acceptable quality level.

24. Packing: price tagging, folding, poly, assorting & cartooning are doing here as per instruction of PO sheet to ready the goods for inspection.

25. Internal Audit: Internal QA/ GPQ will conduct internal audit/ pre-final inspection to check ready goods & packing method including accessories are as per requirement. Then offer customer nominated Inspector for final inspection.

26. Final Inspection: Buyer assign quality team conduct final inspection according to the customer instructions.

27. Shipment: Finally after getting inspection pass, Then goods load to vehicle and send to port for shipment.🚒😀

This is all about manufacturing sweater product. If you think to add more points here, please help to improve this post for others reader.

Implementation of 5S in Garments Industry

noreply@blogger.com (Unknown) — Mon, 04 Oct 2021 09:26:00 +0000

What is 5S in garments Industry? Implementation and Benefit of 5S in garments Industry.

To maintain good housekeeping, 5S is the most important tools for any kinds of organization. People also can perform their work very efficiently and effectively. 5S is the principle of Lean manufacturing. Now most of the factories are maintained regularly 5S activities to produce maximum quality production and ensure standard housekeeping.

5S Principle

5S Stand For:

5S is a term formed with the every first letters of 5 Japanese word are mentioned below,

1. Seiri ( Sorting )

2. Seiton ( Set in Order )

3. Seiso ( Shine )

4. Seiketsu ( Standardize )

5. Shitsuke ( Sustain )

Implementation of 5S in garments Industry:

The way of implementing 5S will explain here.

1. Seiri (Sorting): It is all about categorization of all necessary and unnecessary items, equipment in a workplace. Use red tag for marking all the unnecessary items while sorting. Because any not needed equipment may hampered natural flow of work. There have a quote, “IF IN DOUBT, THROUGH IT OUT.” Now remove all unneeded items from working area. All these results in a clean & better work environment.

2. Seiton ( Set in Order ): This is all about ensuring good housekeeping. “ A Place For Everything And Everything In Own Place. So that arranging right things at the right place for quick access and dispose. The objective of Seiton is anyone can find/dispose required item when needed with less time by keeping all item in organized way. To do this-

· Define and mark fixed place for every item separately.

· Put color code, names, number while storing to make it specific.

This results create the opportunity for higher productivity.

3. Seiso (Shine): It is all about always keep neat and clean all equipment involve for the production including workplace. To confirm this, follow below matters on regular basis-

· All machineries are in good condition & make a check list for servicing.

· Keep clean workplace so that no spotty / dirty garments. Fixed 2/3 times in a day to clean all those things by operator themselves. Can use alarm to fix the cleaning time. Make responsible to follow it regularly. Don’t wait until the work space gets dirty.

This results will ensure good housekeeping & right quality of products.

4. Seiketsu ( Standardize ): Now times to make all first three activities in Standard way. Right work standard creates higher quality & productivity on workplace.

5. Shitsuke ( Sustain ): Now we are on final stage of 5S. After successful installation of first 3S & make them standard, have to maintain it properly and of course regularly. There is no results if not maintain it after doing all those initiatives. Make checklist of every steps and put responsible person to follow up regularly.

Benefits of 5S:

Maintaining good housekeeping & working environment.
Visible all items properly so that anyone can perform in case of absenteeism.
Improve worker performance/ Labor productivity.
Higher productivity & perfect quality.

5S is NOT one time activity. Practice those steps always and everywhere to make it habit not a request.

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How to Reduce Cost per Minute (CPM) in a factory

What is CPM? How to Calculate Cost Per Minute In A Production Line?

Organogram of Industrial Engineering department in a Manufacturing Unit

What is line Planning? Benifits of line planning.

Define Takt Time. Use of Takt Time in Apperal Industry.

How Many Lines Required To Complete an Order of 30000 Pieces?

How To Calculate Average SMV Of a Factory While Produce Different Style Last Month?

What is Man to Machine Ratio and How to Measure Man to Machine Ratio In Garments Industry?

How to Calculate Production Capacity of a Factory ?

How Many Days Required To Complete an Order Of 45000 Pieces?

Style Closing Report And Its Importance For Manufacturing Unit

Difference between Production and Productivity in a Manufacturing Unit

Difference between Productivity & Efficiency

Difference Between Defect and Defective Product with Example. How to Measured those?

What is DHU? How to Measure DHU In A Manufacturing Unit?

Different types of major defects of sweater factories

Sweater Manufacturing Process A to Z – Flow Chart

Implementation of 5S in Garments Industry