Machine Lay Out Setup for Jeans Pant in Apparel Industry
Denim Jeans Manufacturing Process in Apparel Sector:
Jeans is one of the most used apparel for all types of people in today’s fashionable era. To make the targeted number of denim jeans in a limited time we have to follow a correct machine layout. Otherwise we may fail to achieve our targeted jeans production. As its important ace, this article has presented the actual machine layout plan for denim jeans production.
![]() |
Fig: Sewing machine lay out for jeans pant manufacturing |
SL No.
|
Name of Operations
|
Machine Required
|
Standard Time
|
Operator Allocation
|
01
|
Hem watch pocket mouth
|
1-ndl lock stitch with thread trimmer
|
7”
|
Operator-1
|
02
|
Fold watch pocket
|
Manual
|
24”
|
Operator-2
|
03
|
Attach watch pocket
|
1-ndl lock stitch with thread trimmer
|
16”
|
Operator-1
|
04
|
Att. Side pocket facing to pocket bag
|
1-ndl lock stitch with thread trimmer
|
24”
|
Operator-3
|
05
|
Close side pocket bag
|
2-ndl 5 thread safety stitcher
|
18”
|
Operator-4
|
06
|
Att. Side pocket bag to right front
|
1-ndl lock stitch with thread trimmer
|
18”
|
Operator-5
|
07
|
Att. Side pocket facing to pocket bag
|
1-ndl lock stitch with thread trimmer
|
24”
|
Operator-6
|
08
|
Close left side pocket bag
|
2-ndl 5 thread safety stitcher
|
18”
|
Operator-7
|
09
|
Att. Side pocket bag to left front
|
1-ndl lock stitch with thread trimmer
|
18”
|
Operator-8
|
10
|
Att. Zipper to right front fly
|
1-ndl over lock machine
|
6”
|
Operator-9
|
11
|
Serge left front
|
1-ndl over lock machine
|
6”
|
Operator-9
|
12
|
Attach left front fly
|
1-ndl lock stitch with thread trimmer
|
12”
|
Operator-9
|
13
|
Counter stitch left from fly
|
1-ndl lock stitch with thread trimmer
|
20”
|
Operator-10
|
14
|
Top stitch pocket mouth
|
2-ndl lock stitch with thread trimmer
|
20”
|
Operator-11
|
15
|
Top stitch left front fly
|
2-ndl lock stitch with thread trimmer
|
10”
|
Operator-12
|
16
|
Top stitch right front fly
|
2-ndl lock stitch with thread trimmer
|
10”
|
Operator-12
|
17
|
Cut & fold care label
|
Auto label cutting & folding m/c
|
3”
|
Operator-12
|
18
|
Baste pocket bag top
|
1-ndl lock stitch with thread trimmer
|
38”
|
Operator-13, 14
|
19
|
Top stitch crotch
|
2-ndl lock stitch with thread trimmer
|
24”
|
Operator-15
|
20
|
Bar tack front fly
|
Bar tack machine
|
18”
|
Operator-16
|
21
|
Attach yoke to back
|
Flatbd dbl. chain stitch machine
|
18”
|
Operator-17
|
22
|
Hem hip pocket mouth
|
1-ndl lock stitch with thread trimmer
|
24”
|
Operator-18
|
23
|
Decorative stitch to hip pocket
|
1-ndl lock stitch with thread trimmer
|
48”
|
Operator-19, 20
|
24
|
Fold hip pocket
|
Pocket folding machine
|
24”
|
Operator-21
|
25
|
Attach hip pocket to back
|
1-ndl lock stitch with thread trimmer
|
48”
|
Operator-22, 23
|
26
|
Bar tack hip pocket edge
|
Bar tack machine
|
24”
|
Operator-24
|
27
|
Seat seam
|
Feed of the arm dbl. chain stitch machine
|
24”
|
Operator-25
|
28
|
Side seam
|
Feed of the arm dbl. chain stitch machine
|
40”
|
Operator-26, 27
|
29
|
Inside seam
|
2-ndl 5 thread safety stitcher
|
38”
|
Operator-28, 29
|
30
|
Attach waistband
|
Flatbd dbl. chain stitch machine
|
38”
|
Operator-30, 31
|
31
|
Cut & fold waistband corner
|
Manual
|
12”
|
Operator-32
|
32
|
Top stitch waistband corner
|
1-ndl lock stitch with thread trimmer
|
38”
|
Operator-33, 34
|
33
|
Make belt loops (5pcs)
|
2-ndl bottom cover stitch machine
|
6”
|
Operator-32
|
34
|
Attach belt loops
|
Bar tack machine
|
69”
|
Operator-35, 36, 37
|
35
|
Att. Leathered label to waistband
|
1-ndl lock stitch with thread trimmer
|
18”
|
Operator-38
|
36
|
Hem bottom
|
1-ndl lock stitch with thread trimmer
|
40”
|
Operator-39, 40
|
37
|
Sew eyelet buttonhole
|
Eyelet buttonhole sewing machine
|
10”
|
Operator-41
|
38
|
Attach metal button
|
Metal button fastening machine
|
10”
|
Operator-41
|
39
|
Attach rivet
|
Riveter
|
25”
|
Operator-42
|
Total standard time
|
892”
|
Average Process Time Calculation:
Average process time, = (892/39)
= 22.87”
Calculation of BPT, UCL, LCL, Organization Efficiency & Production Target Per Hour:
Production target per hour with 42 sewing operators,
= {(42×3600×0.85)/892}
= 144pcs per hour
Again,
Bottleneck time= 24 second,
So,
Production per hour stands at,
= (3600/24)
= 150pcs per hour.
Now,
Basic pitch time (BPT) is,
= (892/42)
= 21.23”
Again,
Upper control limit (UCL) stands at,
= (21.23”/0.85)
= 24.97”
Again,
Lower control limit (LCL) stands at,
= {2 × (BPT-UCL)}
= (42.46-24.97”)
= 17.49”
Now,
Organization efficient stands at,
= (BPT/Bottleneck time)
= {(21.23”/24”) × 100}
= 88.45%
Again,
Direct productivity stands at,
= (150/42)
= 3.57 pcs per operator per hour