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.
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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