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 |
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SL No.
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Name of Operations
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Machine Required
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Standard Time
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Operator Allocation
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01
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Hem watch pocket mouth
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1-ndl lock stitch with thread trimmer
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7”
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Operator-1
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02
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Fold watch pocket
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Manual
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24”
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Operator-2
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03
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Attach watch pocket
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1-ndl lock stitch with thread trimmer
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16”
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Operator-1
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04
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Att. Side pocket facing to pocket bag
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1-ndl lock stitch with thread trimmer
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24”
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Operator-3
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05
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Close side pocket bag
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2-ndl 5 thread safety stitcher
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18”
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Operator-4
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06
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Att. Side pocket bag to right front
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1-ndl lock stitch with thread trimmer
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18”
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Operator-5
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07
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Att. Side pocket facing to pocket bag
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1-ndl lock stitch with thread trimmer
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24”
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Operator-6
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08
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Close left side pocket bag
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2-ndl 5 thread safety stitcher
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18”
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Operator-7
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09
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Att. Side pocket bag to left front
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1-ndl lock stitch with thread trimmer
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18”
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Operator-8
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10
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Att. Zipper to right front fly
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1-ndl over lock machine
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6”
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Operator-9
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11
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Serge left front
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1-ndl over lock machine
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6”
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Operator-9
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12
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Attach left front fly
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1-ndl lock stitch with thread trimmer
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12”
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Operator-9
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13
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Counter stitch left from fly
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1-ndl lock stitch with thread trimmer
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20”
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Operator-10
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14
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Top stitch pocket mouth
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2-ndl lock stitch with thread trimmer
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20”
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Operator-11
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15
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Top stitch left front fly
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2-ndl lock stitch with thread trimmer
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10”
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Operator-12
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16
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Top stitch right front fly
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2-ndl lock stitch with thread trimmer
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10”
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Operator-12
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17
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Cut & fold care label
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Auto label cutting & folding m/c
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3”
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Operator-12
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18
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Baste pocket bag top
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1-ndl lock stitch with thread trimmer
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38”
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Operator-13, 14
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19
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Top stitch crotch
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2-ndl lock stitch with thread trimmer
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24”
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Operator-15
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20
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Bar tack front fly
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Bar tack machine
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18”
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Operator-16
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21
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Attach yoke to back
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Flatbd dbl. chain stitch machine
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18”
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Operator-17
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22
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Hem hip pocket mouth
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1-ndl lock stitch with thread trimmer
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24”
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Operator-18
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23
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Decorative stitch to hip pocket
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1-ndl lock stitch with thread trimmer
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48”
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Operator-19, 20
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24
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Fold hip pocket
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Pocket folding machine
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24”
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Operator-21
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25
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Attach hip pocket to back
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1-ndl lock stitch with thread trimmer
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48”
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Operator-22, 23
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26
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Bar tack hip pocket edge
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Bar tack machine
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24”
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Operator-24
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27
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Seat seam
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Feed of the arm dbl. chain stitch machine
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24”
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Operator-25
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28
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Side seam
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Feed of the arm dbl. chain stitch machine
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40”
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Operator-26, 27
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29
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Inside seam
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2-ndl 5 thread safety stitcher
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38”
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Operator-28, 29
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30
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Attach waistband
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Flatbd dbl. chain stitch machine
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38”
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Operator-30, 31
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31
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Cut & fold waistband corner
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Manual
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12”
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Operator-32
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32
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Top stitch waistband corner
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1-ndl lock stitch with thread trimmer
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38”
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Operator-33, 34
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33
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Make belt loops (5pcs)
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2-ndl bottom cover stitch machine
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6”
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Operator-32
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34
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Attach belt loops
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Bar tack machine
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69”
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Operator-35, 36, 37
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35
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Att. Leathered label to waistband
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1-ndl lock stitch with thread trimmer
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18”
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Operator-38
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36
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Hem bottom
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1-ndl lock stitch with thread trimmer
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40”
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Operator-39, 40
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37
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Sew eyelet buttonhole
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Eyelet buttonhole sewing machine
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10”
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Operator-41
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38
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Attach metal button
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Metal button fastening machine
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10”
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Operator-41
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39
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Attach rivet
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Riveter
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25”
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Operator-42
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Total standard time
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892”
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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
