How to Setup Machine Layout for Basic Woven Shirt in Apparel Industry?
Woven Shirt Sewing Production Line Layout in Apparel Industry:
Fig: Woven shirt machine layout in apparel industry |
Machine Layout for Woven Shirt in Apparel Manufacturing Sector:
Machine Lay Out Plan for Shirt Body:
SL No.
|
Name of Operations
|
Machine Required
|
Standard Time
|
Operator Allocation
|
01
|
Attach top center to left front
|
4-ndl double chain stitch machine
|
24”
|
Operator-1
|
02
|
Hem pocket mouth
|
1-ndl lock stitch with thread trimmer
|
12”
|
Operator-2,3
|
03
|
Fold pocket
|
Manual
|
42”
|
Operator-4,5
|
04
|
Attach pocket
|
1-ndl lock stitch with thread trimmer
|
40”
|
Operator-2,3
|
05
|
Hem right front button stand
|
1-ndl lock stitch with hemmer folder
|
24”
|
Operator-6
|
06
|
Cut & fold label
|
Label cutting & folding machine
|
3”
|
Operator-7
|
07
|
Attach label to under yoke
|
1-ndl lock stitch with thread trimmer
|
16”
|
Operator-7
|
08
|
Back yoke attach sewing
|
1-ndl lock stitch with thread trimmer
|
24”
|
Operator-8
|
09
|
Back yoke top stitch
|
1-ndl lock stitch with thread trimmer
|
19”
|
Operator-9
|
10
|
Shoulder join
|
1-ndl lock stitch with thread trimmer
|
46”
|
Operator-10, 11
|
11
|
Top stitch on shoulder join
|
1-ndl lock stitch with thread trimmer
|
24”
|
Operator-12
|
12
|
Attach sleeves
|
2-ndl 5-thread safety stitcher
|
48”
|
Operator-13, 14
|
13
|
Side seam
|
2-ndl feed of the arm machine
|
46”
|
Operator-15, 16
|
14
|
Collar attach sew
|
1-ndl lock stitch with thread trimmer
|
40”
|
Operator-17, 18
|
15
|
Collar attach stitch
|
1-ndl lock stitch with thread trimmer
|
40”
|
Operator-19, 20
|
16
|
Hem body bottom
|
1-ndl lock stitch with thread trimmer with hemmer foot
|
24”
|
Operator-21
|
17
|
Attach cuffs
|
1-ndl lock stitch with cuff folder
|
48”
|
Operator-22, 23
|
18
|
Button sewing
|
Button sewing machine
|
38”
|
Operator-24, 25
|
19
|
Buttonhole sewing
|
Buttonhole sewing machine
|
36”
|
Operator-26, 27
|
Total standard time for body processes
|
594”
|
Average Process Time Calculation Method:
Average process time,
= (594/19)
= 31.26”
Calculation of BPT, UCL, LCL, Organization Efficiency & Production Target Per Hour:
Production target per hour with 27 operators,
= {(27×3600×0.85)/594}
= 139pcs per hour
Again,
Bottleneck time= 26 second,
So,
Production per hour,
= (3600/26)
= 138pcs per hour.
Now,
Basic pitch time (BPT) is,
= (594/27)
= 22”
Again,
Upper control limit (UCL) is,
= (22”/0.85)
= 25.88”
Again,
Lower control limit (LCL) is,
= {2 × (BPT-UCL)}
= (44-25.88”)
= 18.12”
Now,
Organization efficiency is,
= (BPT/Bottleneck time)
= {(22”/26”) × 100}
= 84.66%
Again,
Direct productivity is,
= (138/27)
= 5.11 pcs per operator per hour
SL No.
|
Name of Operations
|
Machine Required
|
Standard Time
|
Operator Allocation
|
Collar Processes
|
||||
Fp-1
|
Fuse interlining
|
Fusing press
|
6”
|
Operator-Fp-1
|
Clr-2
|
Sew collar
|
1-ndl lock stitch with thread trimmer
|
24”
|
Operator-1
|
Clr-3
|
Cut collar tip & turn
|
Manual
|
22”
|
Operator-2
|
Clr-4
|
Form collar
|
Collar forming machine
|
20”
|
Operator-3
|
Clr-5
|
Press collar
|
Manual
|
20”
|
Operator-4
|
Clr-6
|
Top stitch collar
|
1-ndl lock stitch with thread trimmer
|
16”
|
Operator-5
|
Clr-7
|
Sew collar bottom
|
1-ndl lock stitch with thread trimmer
|
8”
|
Operator-5
|
Clr-8
|
Trim collar bottom
|
Collar contour trimmer
|
6”
|
Operator-6
|
Fp-1
|
Fuse interlining to band
|
Fusing press
|
6”
|
Operator-Fp-1
|
Clr-9
|
Feel or roll band
|
1-ndl lock stitch with thread trimmer
|
18”
|
Operator-6
|
Clr-10
|
Collar band attach sewing
|
1-ndl lock stitch with thread trimmer
|
24”
|
Operator-7
|
Clr-11
|
Turn band
|
Manual
|
10”
|
Operator-8
|
Clr-12
|
Collar band attach stitch
|
1-ndl lock stitch with thread trimmer
|
18”
|
Operator-9
|
Clr-13
|
Cut band bottom
|
Over lock machine
|
6v
|
Operator-9
|
Clr-14
|
Mark 3-point on collar
|
Manual
|
12”
|
Operator-8
|
Cuff Processes
|
||||
Fp-1
|
Fuse interlining
|
Fusing press
|
12”
|
Operator-Fp-1
|
Cf-2
|
Fell or roll cuff
|
1-ndl lock stitch with thread trimmer
|
18”
|
Operator-10, 11
|
Cf-3
|
Sew or run stitch cuffs
|
1-ndl lock stitch with thread trimmer
|
30”
|
Operator-10, 11
|
Cf-4
|
Fold inside
|
Iron or vacuum board
|
8”
|
Operator-12
|
Cf-5
|
Turn cuffs
|
Manual or iron
|
12”
|
Operator-12
|
Cf-6
|
Form cuffs
|
Cuff forming machine
|
24”
|
Operator-13
|
Cf-7
|
Top stitch cuffs
|
1-ndl lock stitch with thread trimmer
|
18”
|
Operator-14
|
Cf-8
|
Cuff pair match
|
Manual
|
6”
|
Operator-15
|
Sleeve Processes
|
||||
Slv-1
|
Sew under placket to sleeve
|
1-ndl lock stitch with thread trimmer
|
18”
|
Operator-15
|
Slv-2
|
Fold upper placket
|
Manual
|
24”
|
Operator-16
|
Slv-3
|
Attach sleeve placket
|
1-ndl lock stitch with thread trimmer
|
36”
|
Operator-17, 18
|
Total standard time for collar, cuff & sleeves
|
422”
|
Average Process Time Calculation Method:
Average process time,
= (422/24)
= 17.58”
Calculation of BPT, UCL, LCL, Organization Efficiency & Production Target Per Hour:
Production target per hour with 19 operators,
= {(19×3600×0.85)/422}
= 143pcs per hour
Again,
Bottleneck time= 24 seconds,
So,
Production per hour is,
= (3600/24)
= 150pcs per hour
Now,
Basic pitch time (BPT) is,
= (422/19)
= 22.21”
Again,
Upper control limit (UCL) is,
= (22.21”/0.85)
= 26.13”
Again,
Lower control limit (LCL) is,
= {2 × (BPT-UCL)}
= (44.42-26.13”)
= 18.29”
Now,
Organization efficiency is,
= (BPT/Bottleneck time)
= {(22.21”/24”) × 100}
= 97.66%
Again,
Direct productivity is,
= (150/18)
= 8.33 pcs per operator per hour