How to Calculate Minute Cost of Sewing Line in Garments Industry?

Method for Calculating Cost Per Minute of Sewing Line in Garments Industry:

An industrial engineer can easily calculate cost per minute of sewing line in apparel industry by following the two different formulas. Those are in the below:

1. Cost per minute of sewing line,

2. Cost per minute of sewing line,

Now, two examples are enough to clear all the confusions from the above discussion.

Example for the formula number-01:

Suppose, in Nishat garments ltd. total salary of sewing line for one day is 10000taka, no. of manpower’s for 20 machines is 30 and line efficiency is 50%, then calculate cost per minute in 8 working hours of each sewing line for that garments.

Solution:

Here,

Total salary of sewing line for one day = 10000 taka,
Total no. of manpower’s = 30,
Total working hours = 8,
Line efficiency= 50% = 0.5

Now,

Cost per minute of sewing line,

= 1.39 taka

So, cost per minute for each sewing line of nishat garments is 1.39 taka.

Example for the formula number-02:

Suppose, in Abonty fashion ltd. actual salary per day of all the operators and helpers is 15000, total garments produced per day is 400, where standard allowed minutes (SAM) for the garments is 20. Then calculate cost per minute of each sewing line for that garments.

Solution:

Here,

Actual salary per day of all the operators and helpers = 15000,
Total no. of garments produced = 400,
Standard Allowed Minutes (SAM) for the garments = 20

Now,

Cost per minute of sewings line,

= 1.875 taka

So, Cost per minute of sewing line is 1.875 taka.

How to Calculate Line efficiency of Garment Production

Calculation Method for Line Efficiency of a Garment Production:

An industrial engineer has to confirm the following items before starting the calculation method for line efficiency of a garment production:

1. Production output from the line (Pcs),
2. Standard allowed minutes (SAM) for garments,
3. Total number of operators in the line,
4. Total working hours.

Now, by applying all the above items in the below formula, an industrial engineer can easily estimate the line efficiency of a garment production.

Line Efficiency (%),

Now, one example is enough to remove all the confusions from the above discussion.

Example:

In Zara Fashion Ltd. a garment production line produced 300pcs Sweet shirt garments in 45 Standard allowed minutes (SAM) by using 40 operators, where working hours was 8.

Now, estimate the lines efficiency for the mentioned garment production.

Solution:

Here,
Production output from the line- 300pcs
Standard allowed minutes (SAM) for Sweet shirt garments – 45
Total number of operators in the line – 40
Total working hours – 8hrs

Now, by using the following formula, industrial engineer can estimate easily the line’s efficiency of the mentioned garment production.

Line Efficiency (%),

= 70.3%

So, lines efficiency of the mentioned sweet shirt garments production stands at 70.3%

How to Calculate Machine Capacity in Garements Industry?

Machine (hr) Capacity:

Machine (hr) capacity of a garment factory is totally related with number of sewing lines, sewing machines and working hours per day. Its directly proportional to the multiple result of those i.e. number of sewing line, sewing machine and working hours per day.

Sewing machine capacity

Machine Capacity Calculation in Garments Industry:

For calculating machine (hr) capacity in garments industry, we have needed the following information:

1. Sewing line in that factory,
2. Machines in each sewing line,
3. Working hours per day.

Now, by using the below formula, we can easily calculate the machine (hr) capacity in apparel industry.

Machine capacity,

= No. of sewing line in that factory × No. of machines in each sewing line × Working hours per day

Example:

Suppose, Lanny Fashions Ltd. has 10 sewing lines where each sewing line has 20 machines and working hours per day for the factory is 8, then calculate the machine capacity for that factory.

Solution:

Here,

No. of sewing line in that factory= 10
No. of machines in each sewing line= 20
Working hours per day= 8

So,

Machine capacity,

= No. of sewing line in that factory × No. of machines in each sewing line × Working hours per day= 10 × 20 × 8
= 1600hrs.

So, Machine (hr) capacity for the above garments factory is 1600 hrs.

How to Calculate Production Capacity of a Garment Factory?

Introduction:

Production capacity estimation for a garment factory is an important issue in ready made garments sector. It plays an important role to the buyer for selecting right vendor for their orders. How much a garment factory can produce their items per day has estimated here. As its importance in garments manufacturing sector, today I will present here the production capacity estimation method for a garment factory.

Production Capacity:

Production capacity of a garment factory is totally related with machine (hr) capacity, line efficiency of that factory and standard allowed minute (SAM) of produced item. For achieving accurate production capacity of a garment factory, an industrial engineer should confirm accurate cutting room capacity, finishing room capacity and washing capacity also.

Production in garment factory

Production Capacity Calculation Method of a Garment Factory:

For calculating production capacity of a garment factory, an industrial engineer should confirm the below information:

1. Machine (hr) capacity per day,
2. Individual product’s standard allowed minute (SAM),
3. Line efficiency of garment factory or factory efficiency.

Now, by using the following formula, an industrial engineer can easily calculate production capacity of a garment factory.

Production capacity (Pcs),

Example:

Suppose, Noman Fashion Ltd. has 10 sewing lines, each sewing line has 20 machines. They have to produce basic knitted polo shirt items at 8hrs working day, (where machine-hr capacity is 1600hrs and line efficiency is 60%).

So, find out the production capacity of that factory.

Solution:

Here,

Machine (hr) capacity per day= 1600hrs,

Line efficiency of garment factory= 60%,

Standard allowed minute (SAM) for knitted polo shirt= 20

So,

Production capacity (Pcs),

= 2880pcs

So, garments production capacity of the above factory is 2880 pcs per day.

Packing List

What is Packing List in Import Export Business?

Packing list is one of the most important documents for both apparel merchandising and commercial department of an apparel manufacturing industry. Packing section is the part of finishing section of ready made apparel industry. Normally, packing section packs the goods as per ratio or assortment. In the later, apparel inspector inspects the apparel product according to apparel packing list.

To prepare final packing lists, commercial department of an apparel industry has needed the final packing list for forwarding agents and customs department. From here, they calculate the total shipping volume and weight to confirm the required shipping cargo. As its importance, both apparel merchandiser and commercial personnel should aware about it to reduce cost in shipping.

You may follow What Types of Documents Required for Apparel Buyer?

Types of Packing in Finishing Section:

There are so many packing types followed in apparel industry. The following are the most used among those:

1. Flat pack (Shirt, sportswear, trouser),
2. Stand up pack (90° angle),
3. Semi-stand up pack (for shirt),
4. Hanger pack (for coats, blazer, pants),
5. Half fold pack (for pant).

Types of Carton Packing in Apparel Industry:

After packing the apparel, cartooning is done according to the apparel size and color in apparel manufacturing sector.  Mostly used carton packing types have given in the below though there are various types of cartoon packing in clothing sector:

1. Solid color solid size carton packing,
2. Solid color assorted size carton packing,
3. Assorted color solid size carton packing,
4. Assorted color assorted carton packing.

It should be noted here that, carton packing may be as 12pcs, 24pcs or 36pcs per carton which is totally dependent on the buyer requirements.

Packing List Documents in Apparel Sector:

Packing list (P/L) is known as an inventory of the incoming cargo which is required for customs clearance in apparel shipment and accompanying the commercial invoice and the transport documents.

During apparel shipment, packing list generally includes the below information’s or documents:

1. Name of the exporter,
2. Name of the importer,
3. Name of the transport company,
4. Date of issue,
5. Number of the freight invoice,
6. Type of packaging (carton, box, barrel, bag, etc.),
7. Total number of packages,
8. Content of each package (Details description of the goods and number of items per package),
9. Marks and numbers,
10. Gross weight, net weight, and measurement of the packages.

Packing List Format in Apparel Industry:

An expert said that, packing lists should start with date, buyer order and style number of product, carton number. Unsorted summary also not accepted by the buyers.  Intact, some buyers may even ask for net weight and gross weight of each carton. The below format have to maintain during carton packing.

Garments Manufacturing Process Flow Chart

Garments Manufacturing:

A complete garment has to face several processes from its order receiving to shipment. During garments manufacturing, a process flow chart must be needed to complete an order easily. Also a process flow chart helps to understand a garment manufacturing method that how the raw materials are converted into the wearable garments.

Garments Manufacturing Process

Flow Chart of Garments Manufacturing Process / Technology:

A basic garment manufacturing flow chart is presented in the below:

Design
↓
Pattern Making
↓
Fit Sample Making
↓
Production Pattern Making
↓
Grading
↓
Marker Making
↓
Fabric Spreading
↓
Fabric Cutting
↓
Cutting Parts Sorting or Bundling
↓
Sewing
↓
Garments Inspection
↓
Garments Ironing and Finishing
↓
Final Inspection
↓
Garments Packing
↓
Cartooning
↓
Shipment

Each process of garments manufacturing flow chart is discussed in the below with the details:

1. Design:
Design is provided by the buyer. After placing an order buyer send the technical sheet and art-work of an order to the merchandiser. This process is done by both manually or by using computer.

2. Pattern Making:
By following technical sheet and art-work, pattern of each garment style should be made. It’s done by both manually and by using computerized method.

3. Fit Sample Making:
The main target of making a fit sample is to follow the details instruction about that garments style. After making it’s sent to the buyer to rectify. It’s done by manually.

4. Production Pattern Making:
For bulk production, allowance added here with net dimension. Production Pattern Making is done by both manually and by using computer.

5. Grading:
During an order confirmation, the buyer suggests about the size ratio of that order. So that order should be graded according to the buyer’s instruction. Grading is done by manually or by using computer.

6. Marker Making:
Marker is a very thin paper which contains all the parts of a particular garment. To make the cutting process easy, it’s must be needed. Marker making process can be done by both manually and by using computer.

7. Fabric Spreading:
To cut the fabric properly fabric is spread in lay form. Fabric Spreading is done by manually or by using computerized method.

8. Fabric Cutting:
Fabrics have to cut here according to marker of garments. Fabric Cutting process is done by using manual method or computerized method.

9. Cutting Parts Sorting or Bundling:
Here, cutting parts have to sort out or make bundling to send these easily into the next process. This process is done by manually.

10. Sewing:
All the parts of a garment are joined here to make a complete garment. Sewing process is done by manually.

11. Garments Inspection:
After completing sewing, inspection should be done here to make fault free garments. Garments Inspection is done by using manual method.

12. Garments Ironing and Finishing:
Here garments are treated by steam; also required finishing should be completed here. This process is done by using manual method.

13. Final Inspection:
Finally the complete garments are inspected here according to the buyer’s specification. Final Inspection is done by manual method.

14. Garments Packing:
Complete garments are packed here by using buyers instructed poly bag. Garments packing are done by using manual method.

15. Cartooning:
To minimize the damages of garments, all the garments have to cartooned by maintaining buyers instruction. This process is done by manually.

16. Shipment:
After completing all the required processes it’s finally send to the buyer.

Duties of a Sewing Machine Operator in Apparel Sector

The sewing operators accomplish the real job of apparel manufacturing. All the other people do the auxiliary works. Operators must know what they must perform and what level of performance; skill and workmanship are required from them. So, a job description in writing must be provided to the sewing machine operator. If sewing machine operator is illiterate each point of the job description must be described to him so that he takes the job seriously and can accomplish it as desired.

Sewing machine operator works in apparel industry

Job Descriptions for Apparel Production Sewer or  Sewing Machine Operator:

1. Sewing machine operator will come to the floor in time & shall clean machine, workplace etc.
2. He will check 7 ensure that his workstation is in right order.
3. He will seek necessary instruction from here supervisor regarding his job.
4. He will seek mock up sample from her supervisors so that he can understand the job.
5. He will check the mock up sample so as to understand the sewing technique & the level of quality.
6. He will check with the supervisor regarding his hourly & daily production target.
7. If he does not understand any point regarding sewing or quality, he will seek elaboration from supervisor.
8. Sewing machine operator will ensure measurements of apparel as per work order sheet or apparel specification sheet.
9. He will ensure necessary seam allowances as per instruction.
10. He will perform his job with utmost care so that no reject or defect occurs.
11. He will handle apparel parts with care so that they do not spoil or stain.
12. He will take care in handling bundles and parts in them so that they do not mix-up.
13. He must see that he accomplishes his target.
14. If there is any bottleneck, he will discuss with the supervisor & take countermeasures.
15. He will check needle from time to time to ensure that it is not blunt or broken.
16. He will take care that there is no under sewing thread tension.
17. Sewing machine operator will ensure that stitch per inch (SPI) is correct.
18. He will clean his sewing machine from time to time.
19. He will take care of his machine.
20. He will ensure that the designated machine cleans the machine, oils it, & takes care of it.
21. He will continuously check if her work is compatible with the quality & quantity desired.
22. He will discuss with the supervisor & senior operators about sewing problems or sewing defects and sewing techniques.
23. He will ensure that his machine is equipped with eye guard or needle guard or puller cover.
24. He will get trained on using firefighting equipment & how to face an accident.
25. He will use mask all the time to offset micro dust.
26. He will use hand gloves and scarf.
27. Sewing machine operator will not panic at the time of hazard or fire disaster.

Garments Wash Care Symbols |

This guide explains what the washing and clothing care symbols on your garment labels say about how you should wash, dry, iron and bleach your clothes – taking you through all the essential steps of taking care of your wardrobe. The following wash care symbols cover how your garment should be cleaned:

Once you've washed your clothes, it's just as important to dry them properly. The following wash care symbols explain whether it is safe to use a tumble dryer after washing your garment, and if so, which setting is appropriate.

If you prefer to dry your clothes naturally, the following clothing care symbols explain the best method to use without damaging your clothes:

Once your clothes are dry, ironing becomes a priority: these wash care symbols explain how (and whether) your clothes should be ironed.

If your whites are looking a bit drab and grey, you should check for these wash care symbols before attempting to use bleach. It is also important to check the label of your product to ensure you use it properly and take the necessary safety precautions. 

(Use biocides safely. Always read the label and product information before use.)

Finally, some special garments are better off being taken care of by a professional; these wash care symbols cover whether your clothing should be dry cleaned

If you have any clothing care tips of your own, we'd love to hear from you! Share them with us in the comment box below.

Over Dyeing & Tinting of Garments |

Tinting & Over Dyeing: 

After denim pant is being faded, the pants have dyed with very light color(.001% or .002%yellow or pink). This dyeing process is called Tinting/Over dyeing .This process is applied only on garments, not in fabric or yarn.

Tinting and over dyeing can be highlighted by the following way:

1. This type of process is done after different types of washing before softening.
2. Normally after Acid wash, Stone wash, Stone enzyme wash, Sand Blasting, Enzyme wash etc. tinting & over dyeing is done.
3. Tinting & over dyeing is done with Direct dyes or Reactive dyes.
4. Due to tinting and over dyeing, the white/base area colored with required dye yellow,Brown, Orange etc.
5. As a result, new color effect is produced in the garments.
6. If direct dye is used then color fixing treatment should be done at the end of dying process. In case over dyeing/Tinting with reactive dyes, color fastness is good hence no after treatment is required to fix the reactive dyes.

Tinting by Direct Dye: 

First Step: After different wet processing i.e. Acid wash, Stone wash, Enzyme wash, Stone enzyme wash, Bleach wash take 60 kg garment for Tinting & over dyeing. 

1. Water at L : R = 1: 7.............. 420 Liter
2. Run the Machine.
3. Temperature................. 50 - 80°c
4. Dir. Brown GTL - at 0.04%........... 24 Gms.
5. Dir. Orange ZTL- at 0.01%........... 6 Gms.
6. Add Salt at 20 gm / liter ............ 8.40 kg.
7. Add Leveling agent at 0.5% /........ 210 gm.
8. Time................................ 10 to 30 mts.
9. Rinse by cold water 3 minutes.

Second Step:  Fixing 

1. Batch size .............................. 60 kg.
2. Water at L : R = 1: 7.............. 420 Liter
3. Run the Machine.
4. Temperature................. 50°c
5. Add fixing agent at 0.8 %(owf) ... 480 gm.
6. Time............................................ 10 mts. 

Third Step:  Softening. 

1. Batch size.................... 60 kg.
2. Water at L : R = 1 : 7 ............................ 420 Liter
3. Add Acetic Acid at 0.6 gm/liter ............ 250 gm.
4. Add Cationic softener at 1 gm/liter ...... 420 gm.
5. Time................................ 10 mts.
6. Drop the liquor.
7. Then unload the garments on trolley. 

Fourth Step:  Hydro extractor machine. 

Hydroextractor machine is used to remove excess water from the garments. Fifth Step: - Dryer machine. After hydro extraction the garments are sent to drying m/c for complete drying. Sixth Step: - Quality & Delivery. After drying the garments go to quality checking & rectify washing fault and then good one delivery. 

Tinting by Reactive dye: 

First Step:  After different wet processing i.e. Acid wash, Stone wash, Enzyme wash, Stone enzyme wash, Bleach wash take 60 kg garment for Tinting & over dyeing. 

1. Water at L : R = 1: 7.... 420 Liter
2. Run the Machine.
3. Temperature................. 60°c
4. Reactive Red
5. Reactive Yellow - Brown ......... 100 gm.
6. Reactive Black -
7. Leveling agent - at 0.5 gm / liter.......240 gm.
8. Salt - at 20 gm / liter........... 8.40 kg.
9. Soda ash at 10 gm / liter ............ 4.20 kg.
10. Time................................ 20 to 30 mts.
11. Drop the liquor.

Second Step:  Fixing. 

1. Batch size.................... 60 kg.
2. Water at L: R = 1 : 8 .............. 480 Liter
3. Run the Machine.
4. Temperature.................................. 50°c
5. Add fixing agent at1 gm / liter..... 480 gm.
6. Time............................................. 10 mts.
7. Drop the liquor.

Third Step:  Softening. 

1. Batch size.................... 60 kg.
2. Water at L : R = 1: 7.............. 420 Liter
3. Add Acetic Acid at 0.6 gm/liter ............ 250 gm.
4. Add Cationic softener at 1 gm/liter ...... 420 gm.
5. Time................................ 10 mts.
6. Drop the liquor.  
7. Then unload the garments on trolley

Fourth Step:  Hydro extractor machine. 

Hydro extractor machine is used to remove excess water from the garments. Fifth Step: - Dryer machine. After hydro extraction the garments are sent to drying m/c for complete drying. Sixth Step: - Quality & Delivery. After drying the garments go to quality checking & rectify washing fault and then good one delivery.