SEWING MACHINE which are used in Garments Industries # 01

Sewing is a creative and interesting skill. The knowledge of sewing give a confident feeling when it is applied to the construction of garments. The earlier method of sewing by hand is not applicable for all stages of garment making. Therefore, considerable emphasis is given to machine sewing. There are several machines in the market today, each with its own desirable features and advantages. Sewing machines range from most basic having only simple lock stitch to the electronic machines that use advanced computer technology having various functions for

Example : piping, binding, ruffling, pleating, darning, hemming and even making buttonholes and attaching fasteners. A good sewing machine is required to obtain quality products. One has to be familiar with the characteristics of different types of machines for selecting appropriate machine, depending upon the ability and requirements of the person. 

1.1 TYPES OF SEWING MACHINES:

Sewing machines are now available in various models such as domestic model, tailor model, industrial model, portable and cabinet models. They may be operated by hand, treadle or electric motor.

Hand – Operated Sewing Machine:

Layout Design And Assembly Line Balancing For Garments Industries

Layout Design For Garments Industries

Layout is one of the key decisions that determine the long-run efficiency of operations.Layout has numerous strategic implications because it establishes an organization’s competitive priorities in regard to the capacity, processes, flexibility and cost as well as quality of work life, customer contact and image. An effective layout can help an organization to achieve a strategy that supports differentiation, low cost, or response (Heizer et al., 2000, p. 336). The layout must consider how to achieve the following:

1. Higher utilization of space, equipment, and people.

2. Improved flow of information, material or people.

3. Improved employee morale and safer working conditions.

4. Improved customer/client interaction.

5. Flexibility (whatever the layout is now, it will need to change).

Knowledge about time studies & method studies for Industrial Engineering.

Time Studies

The classical stopwatch study, or time study, originally proposed by Federic W. Taylor in 1881, is still the most widely used time study method. The time study procedure involves the timing of a sample of worker’s performance and using it to set a standard. A trained and experienced person can establish a standard by following these eight steps (Heizer et al., 2000, p. 409-412).

1. Define the task to be studied (after methods analysis has been conducted).

2. Divide the task into precise elements (parts of a task that often takes no more than a few seconds).

3. Decide how many times to measure the task (the number of cycles of samples needed).

4. Record elemental times and rating of performance.

5. Compute the average observed cycle time. The average observed cycle time is the arithmetic mean of the times for each element measured, adjusted for unusual influence for each element :

How to Calculate Garments Cost of Manufacturing (CM) | Knit Garments CM Calculation Formula

CM is the abbreviation for Cost of Manufacturing. In apparel industry CM means Manufacturing Cost of 12 pcs garments. To calculate Manufacturing Cost of 12 pcs knit garments of a specific order we must know-

1. Monthly expenditure of the factory,

2. Total running machine,

3. Machine qty to execute the layout of the specific order,

4. Daily (8 hour/day) productivity of the said order (excluding alter and reject) and

5. Dollar conversion rate (if monthly expenditure amount is other than US Dollar)

Suppose,

-Monthly Factory Expenditure is BD Taka 40,00,000
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What Is BOTTLENECK In Garments Production Line? How To Find Out & Reducing BOTTLENECK?

What Is BOTTLENECK In Garments Production Line? How To Find Out & Reducing BOTTLENECK?

Writing By,

Nurul Amin Jibon

IE Executive (Mohammadi Group)

B.Sc In Textile Engineer

Primeasia University. Batch: 091

Phone No : 01687-201045

Bottleneck

The upper narrow portion of a bottle is called neck (opening side) that is an obstruction to go to the way from large portion of bottle through narrow portion of neck. It is a metaphorical scene of obstruction of production sector. It is an extreme point in a production sector where production is hampered from normal flow of production. In a production sector bottleneck means lost production and lost profit e.g. the lowest capacity of production.

Bottleneck in production line

The lowest output point in production line is called bottleneck. The bottleneck area is where supply gathered and production goes under capacity. In the chain working systems the supply of an operator is the feeding of next operator. So, the minimum supply from bottleneck point will be the feeding of 
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What are Allowances & Different types of allowances which are used in garments industries?

Allowance:

The normal time for an operation does not contain any allowances for the worker. It is impossible to work throughout the day even though the most practicable, effective method has been developed. Even under the best working method situation, the job will still demand the expenditure of human effort and some allowance must therefore be made for recovery from fatigue and for relaxation.

Allowances must also be made to enable the worker to attend to his personal needs. The allowances are categorized as:

1. Relaxation Allowance: 

Relaxation allowance may be of two types:

Industrial Engineering ( IE ) for Apparel Manufacturing Industries.

INTRODUCTION

Due to the increasing labor wage in developed countries, the apparel manufacturing has been migrating from the high wage developed world to low wage developing countries (Bheda, Narag and Singla, 2003). Even though the labor cost is cheaper than in developed countries; due to the specific market nature of the garment industries for example: the short production life cycle, high volatility, low predictability, high level of impulse purchase, the quick market response; garment industries are facing the greatest challenges these days (Lucy Daly and Towers, 2004).

Garment industries in developing countries are more focused on sourcing of raw material and minimizing delivery cost than labor productivity because of the availability of cheap labor. Due to this, labor productivity is lower in developing countries than in the developed ones. For example, labour is very cheap in Bangladesh but the productivity is poor among other developing countries (Shahidul and Syed Shazali, 2011). Similarly, the cost of fabric is a major part of the garment so there
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Waste Reduction Techniques for Garments Industries.

Waste Reduction Techniques :
Some of the waste reduction tools include zero defects, setup time reduction, and line balancing. The goal of zero defects is to ensure that products are fault free all the way, through continuous improvement of the manufacturing process (Karlsson and Ahlstrom 1996). Human beings almost invariably will make errors. When errors are made and are not caught then defective parts will appear at the end of the process. However, if the errors can be prevented before they happen then defective
parts can be avoided. One of the tools that the zero defect principle uses is Poka Yoke. Poka-Yoke, which was developed by Shingo, is an autonomous defect control system that is put on a machine that inspects all parts to make sure that there are zero defects. The goal of Poka-Yoke is to observe the defective parts at the source, detect the cause of the defect, and to avoid moving the defective part to the next workstation (Feld, 2000).

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What is the difference between “Production” and “Productivity”?

What is the difference between “Production” and “Productivity”?

Writing By,

Nurul Amin Jibon

IE Executive (Mohammadi Group)

B.Sc In Textile Engineer

Primeasia University. Batch: 091

Phone No : 01687-201045

Production is Conversion of the resources to product which customers demand or the quantity produced within the given time.

Production = Output (Products or Services)

Productivity is the ratio and the relationship between used resources and outputs

Productivity = Output/ Input

Example 01 : A line of operators’ make100 pieces garments in a day. By improving the line balance

How to design at garments Sewing Station? | Seating Arrangement

Employees encounter several risk factors at sewing workstations, such as awkward arm, neck, trunk, and leg postures. These postures are influenced by the size of the worker and the design of the workstation. This section explains potential hazards encountered at the workstation and a general description of a proper workstation design.

• Chair
•  Table
•  Treadle/Pedal

1. Chair:

Potential Hazards: 

Workers often maintain awkward shoulder, elbow, and wrist postures (Fig. 1) while sewing because of improper chair height or position.

Employees must sit or stand for long periods in the same position, resulting in soreness of the back and neck, and/or buttocks, and reduced circulation to the legs.
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Interview Question For Sr. Executive IE Or Work Study Officer.

You have an invitation for an interview and you have to get prepared — where do you start and what do you do? The advice from many is to prepare, prepare, prepare. In general, do your homework. Find out as much as possible about the institution, the department and the professors. Use the Web, your own faculty and fellow students as resources.

What to Do in a Interview :

• Present an air of confidence during your interview and understand what is expected of you.
  
• Do your homework and find out as much as possible about the institution, department and the faculty. Know the institution's Web information.
  
• Tailor your job talk to the attendees and make arrangement for any A/V support in advance.
  
• Keep your job talk general and short. Don't talk about all of the details, but show that you are aware of them.
  
• Address questions about your job and don't be afraid to admit you don't have an answer.
  
• Show interest in your interviewer's work. Read at least one paper written by each person in your area.
  
• Show respect to committee and department staff. Be flexible and polite.
  
• 
  

Interview Question For Work Study Officer / IE Officer.

Job interviews can be a daunting, scary experience but you can ditch the nerves by preparing answers to popular interview questions before you head out the door. 

We take a look at the different types of interview question you can expect to get and offer you advice on how to go about giving answers that will get you the job.

So, it’s interview preparation time. Feeling a bit overwhelmed by everything you have to do? Don’t panic! Take a breath and relax! We've broken it all down for you

5S-Tool of Industrial Engineering

5S:
The first pillar of TPM is called 5S, which organize and cleans work place; this helps to make problems visible and attracts the attentions of everyone. Brief description of 5S elements are as follows:

Sort (Seire): The first step in making things cleaned up and organized.

Set In Order (Seiton): Organize, identify and arrange everything in a work area.

Shine (Seiso): Regular cleaning and maintenance.

Standardize (Seiketsu): Make it easy to maintain, simplify and standardize.

Sustain (Shitsukt): Maintain what has been achieved.
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Total Productive Maintenance (TPM) Implementation of lean manufacturing tools in garment manufacturing process::

Traditionally operated garment industries are facing problems like low productivity,longer production lead time, high rework and rejection, poor line balancing, lowflexibility of style changeover etc.These problems were addressed in this study by the implementation of lean tools like cellular manufacturing, single piece flow, workstandardization, just in time production etc.

4.1 Total Productive Maintenance (TPM)

Machine breakdown is one of the major headaches for people related to production. The reliability of the equipment on the shop floor is very important because if any one of the machines is down the
entire shop floor productivity may be nil. The tool that takes care of these sudden breakdowns and awakes maintenance as well as production workers to minimize these unplanned breakdowns is called total productive maintenance. Total Productive Maintenance (TPM) is a maintenance program, which involves a newly defined concept for maintaining plants and equipment. The goal of the TPM program is to increase production, increase employee morale and job satisfaction. (Bisen and

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Just in Time (JIT) Implementation of lean manufacturing tools in garment manufacturing process

Traditionally operated garment industries are facing problems like low productivity,longer production lead time, high rework and rejection, poor line balancing, lowflexibility of style changeover etc.These problems were addressed in this study by the implementation of lean tools like cellular manufacturing, single piece flow, workstandardization, just in time production etc.

3.1 Just in Time

Just in time is an integrated set of activities designed to achieve high volume production using the minimal inventories of raw materials, work in process and finished goods. Just in time is also based on the logic that nothing will be produced until it is needed (Shivanand, 2006, p. 45).
 

Just-in-time manufacturing is a Japanese management philosophy applied in manufacturing. It involves having the right items with the right quality and quantity in the right place at the right time. The ability to manage inventory (which often accountsfor as much as 80 percent of product cost) to coincide with market demand or changing product specifications can substantially boost profits and 
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Toyota Production System Implementation of lean manufacturing tools

Traditionally operated garment industries are facing problems like low productivity,
longer production lead time, high rework and rejection, poor line balancing, low
flexibility of style changeover etc. These problems were addressed in this study by the
implementation of lean tools like cellular manufacturing, single piece flow, work
standardization, just in time production etc.

2.1 Toyota Production System

It is a manufacturing system developed by Toyota in Japan after World War II, which aims to increase production efficiency by the elimination of waste. The Toyota production system was invented and made to work, by Taiichi Ohno. While analyzing the problems inside the manufacturing environment; Ohno came to conclude that different kinds of wastes (non value added works) are the main cause of inefficiency and low productivity. Ohno identified waste in a number of forms, including overproduction, waiting time, transportation problems, inefficient processing, inventory, and defective products.

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Implementation of lean manufacturing tools in focusing sewing section 01

Traditionally operated garment industries are facing problems like low productivity, longer production lead time, high rework and rejection, poor line balancing, low flexibility of style changeover etc. These problems were addressed in this study by the implementation of lean tools like cellular manufacturing, single piece flow, work standardization, just in time production etc.
After implementation of lean tools, results observed were highly encouraging. Some of the key benefits entail production cycle time decreased by 8%, number of operators required to produce equal amount of garment is decreased by 14%, rework level reduced by 80%, production lead time comes down to one hour from two days, work in progress inventory stays at a maximum of 100 pieces from around 500 to 1500 pieces. Apart from these tangible benefits operator multi-skilling as well as the flexibility of style changeover has been improved.

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1.1 History of Lean

Objectives of implementing TQM in textile factories?

To reduce work in process ( WIP) : 

Work in process means a material that has entered in production process but is not yet a finished product . It is necessary to reduce work process for maintain total quality management that’s why management get output of entered product as soon as possible within required time.

To maintain Critical Path Method ( CPM) : 

Critical path method means how any work or production is complete in accurate but short way by considering all the quality and other factors of production . Management must be walk out by using CPM.

To reduce wastage  : 

Wastage is a common factor for any production . In textile sector , costing of a product is calculated smaller then smallest  . How much you can reduce wastage , you will save more costing which is profitable for company . so that it is necessary to reduce wastage

What Is Production Study? Importance & Procedure of Production Study?

What Is Production Study? Importance & Procedure of Production Study?

Written By,

Nurul Amin Jibon

IE Executive (Mohammadi Group)

B.Sc In Textile Engineer

Primeasia University. Batch: 091

Phone No : 01687-201045

Production study

The second stage of work measurement is the production study that is a very powerful and effective technique of work measurement. It is easy technique to determine the fact about effective or non-effective time that how it is effective or non-effective as well as the causes of their activities. It shows the real picture of work that can be segregated the time feature of every element and their

What is Cycle Time? How to Checking Cycle Time? Importance & Procedure of Cycle Checking?

What is Cycle Time? How to Checking Cycle Time? Importance & Procedure of Cycle Checking?

Written By,

Nurul Amin Jibon

IE Executive (Mohammadi Group)

B.Sc In Textile Engineer

Primeasia University. Batch: 091

Phone No : 01687-201045

Cycle Time

To check how many an operator can produce in one hour.

Cycle check

Cycle check means to check the time of a specific operation or element from starting point to ending point. An operator has to perform an operation or some of operations within an allocated time that is called a cycle and every cycle have to be repeated continue for his/her duty hours.

Cycle checking area

1.         Individual operation or group of operations performing area

2.         Individual worker or group of workers working area.