Textile Healer

Calculating Minute Cost of Sewing Line in Garment Industry Introduction:   Minute cost calculation in sewing line is a common and most important task for textile engineers / industrial engineer. Because maximum earning depends on it. So industrial engineers have to do it very consciously. Cost per minute of sewing line in apparel industry is calculated for sewing operators, helpers, line supervisor and quality checkers. Sewing line in garment industry Methods of Calculating Cost per Minute of a Sewing Line:  There are two types of cost per minute (CPM) of a sewing line in garments factory - Estimated cost per minute of a line Actual cost per minute of a line We can explain in the following way,  1. Cost per minute of sewing line,       Total salary of sewing line for one day  = ………………………………………………    Total minutes available × Line efficiency%                            Total salary of sewing line for one day  = …………………………………………………………………………………    Total no. of man power × daily working ho...

Time Study: Definition, Objectives and Advantages (With Formula)   After reading this article you will learn about:- 1. Definition of Time Study 2. Objectives of Time Study 3. Basic Procedure 4. Advantages 5. Limitations 6. Length 7. Number of Cycles to be Timed. Definition of Time Study: Time study may be defined as “the art of observing and recording the time required to do each detailed element of an industrial activity/operation.” The term industrial activity includes mental, manual and machining operation, where:   (i) Mental time includes time taken by the operator for thinking over some alternative operations. (ii) Manual time consists of three types of operations i.e. related with handling of materials, handling of tools and handling of machines. (iii) Machining time includes time taken by the machines in performing the requisite operations. Thus time study standardizes the time taken by average worker to perform these operations. Objectives of Time Study: The main objectives o...

Motion Study: Meaning, Objectives and ProDespatc In this article we will discuss about:-  1. Meaning of Motion Study  2. Objectives of Method Study/Motion Study  3. Procedure. Meaning of Motion Study: The propounder of this concept was Frank Gilbesth. He defined motion study as the “Science of eliminating wastefulness resulting from ill-directed and inefficient motions”. The main aim of motion study is to find the scheme of least wastage of labour. Subsequently, the scope of Motion Study was enlarged and it was named as Method Study. The method of study can also be defined as “Systematic recording and critical examination of existing and proposed ways of doing work as a means of developing and applying easier and more effective method and thereby reducing cost”. Method Study is a technique which includes the standardisation of equipment, method and working conditions, and training of the operator to follow the standard method. Objectives of Method Study/Motion Study: The important obje...

Standard Minute Value: SMV in Garments, Calculation, Importance The term Standard Minute Value – SMV is mostly used in the garments industry and it is a common measurement calculated by the Industrial Engineer. Generally, SMV indicates the time taken to make garments by the workers using the right types of machinery. In garments factory, you may find that many people used to the SAM – Standard Allowed Minute which is same as SMV. SMV varies garments to garments, style to style, factory to factory. Management and buyers ask for SMV and it is the responsibility of the IE department to calculate SMV and give it to the respective parties. Here in this article, I will share details of Standard Minute Value: SMV in Garments, Calculation, Importance with a practical example. Standard Minute Value: SMV in Garments, Calculation, Importance Industrial Engineering is concerned with the design, improvement, and installation of an integrated system of men, machinery, and materials. SMV is one of th...

Advantages of Time Study: The advantages of time study are the applications to which time standards are put. Generally they are required (a) to plan future production and (b) to evaluate performance of workers or of the production system as a whole. (a) To plan future production they are required for: (1) Estimation of equipment or machinery requirements. (2) Estimation of production cost per unit in order to determine/fix selling price. (3) Estimating manpower requirements. (4) Taking makes or buys decisions. (5) Balancing the work of operators constituting a group. (6) Estimating delivery dates. (7) Estimating times required for a specified inventory level generation.   (8) Estimation of labour costs. (9) Making alternative investment decision in purchasing machines/equipment. (10) Developing efficient plant layout and material handling arrangement. (b) Time standards help in evaluation of performance as in following cases: (1) The evaluation of productivity of various workstations....

Calculating Minute Cost of Sewing Line in Garment Industry Introduction:   Minute cost calculation in sewing line is a common and most important task for textile engineers / industrial engineer. Because maximum earning depends on it. So industrial engineers have to do it very consciously. Cost per minute of sewing line in apparel industry is calculated for sewing operators, helpers, line supervisor and quality checkers. Sewing line in garment industry Methods of Calculating Cost per Minute of a Sewing Line:  There are two types of cost per minute (CPM) of a sewing line in garments factory - Estimated cost per minute of a line Actual cost per minute of a line We can explain in the following way,  1. Cost per minute of sewing line,       Total salary of sewing line for one day  = ………………………………………………    Total minutes available × Line efficiency%                            Total salary of sewing line for one day  = …………………………………………………………………………………    Total no. of man power × daily working ho...

Apparel Sewing Thread Consumption Apparel Professionals often need find out thread consumption of various items like Shirt, Shorts, Tank tops, Pants and so on. Thread consumption means how much thread we need to stitch a product. To calculate thread consumption, we’ve to pay concentration on sewing machines, number of needles, fabric thickness & above all how much thread is used to stitch 1 inch by a machine. And you need consider minimum 10% wastage to find out thread consumption of a product. Information below shows you how much threads you need to stitch 1 inch of fabric. It differs fabric to fabric as on their GSM & construction. Besides you can stitch 10 inches of a fabric, then cut 1 inch stitch, measure the length of each thread, then find out total length of threads & finally add wastage minimum 10%. We know, it’s a long process. Better we can memorize information below & imagine wastage depending on fabric GSM. For fabric with high GSM, we’ve to increase wastag...

How to Calculate WIP level in Cutting, Sewing and Finishing Section? Work in progress (WIP) or  in-process inventory includes the set at large of unfinished items for products in a production process. These items are not yet completed but either just being fabricated or waiting in a queue for further processing or in a buffer storage. In garment manufacturing WIP is generally measured in pieces (unit). WIP can be measured  Total pieces loaded in a process minus total pieces out from that process is the WIP of that process. If you only want to calculate current WIP level or how many pieces are there as a WIP in a section use following formula - Cutting Room WIP:  When one calculates cutting room WIP only stock cut pieces is considered as cutting WIP. Fabric those are layered on table or received from fabric store for cutting is not considered as WIP. Cutting WIP = Total cut qty - Total qty sent to sewing, For example, Cutting room cut total 5000 pieces for style# A and 3000 pieces have ...

Cutting Process in the Garment Industry . Cutting processes followed by the garment factories will be discussed in this post. Fabrics are cut into garment patterns using one of the cutting aids for making garments from fabrics. In the ready-made garment manufacturing, garment manufacturer mostly does cut-to-pack processes. The cutting process comes next to the fabric sourcing and prior to the stitching garments. In the earlier post, cutting room overview explained details about various process performed in the cutting section in the garment factory. In the global apparel sourcing supply chain, garment manufacturers are called export houses and garment suppliers. Here we will see the process flow of the cutting department. The cutting process sequence is shown by arrows. Receiving cut plan and maker plan based on work order --> Preparing cut ratio --> Receiving fabrics from fabric store (warehouse) --> Receiving pattern or markers from the CAD department --> Verify fabric ap...

Principle of motion study 1) Principles relating to movement of human body: The labor has to move his/her body with speed for performing a job. Speed of work cannot be increased without moving body properly. The use of two hands at a time is also important to increase the speed of work. Movement should be reduced for doing all necessary materials, tools, spare parts etc. has to keep very near to the hands. If body movement can be minimized for doing a job, then energy and time will be saved. Have to take rest in between works for removing the tiredness, as a result work speed will be increased and total works will be much more. To remove monotony, have to arrange recreation and ultimately it will give good result. Take care of health and have to arrange first aid that is necessary. Medicines have to keep inside the industry. 2. Principles or rules relating to work station: All necessary materials, tools, spare parts etc. has to keep within the range of two hands of workers at the works...

What is Productivity? Definition, Example and Benefit of Measuring Productivity Productivity Manufacturing Productivity can be given as “OUTPUT” compared to “INPUT”. According to Marsh, Brush (2002) in his article Journal of industrial technology, productivity is a measure of the efficiency and effectiveness to which organizational resources (inputs) are utilized for the creation of products and/or services (outputs). Productivity measurement is both a measure of input utilization and an assessment as to whether or not input utilization is growing faster than output. In the case of a garment manufacturing factory, “output” can be taken as the number of products manufactured, whilst “input” is the people, machinery and factory resources required to create those products within a given time frame. The key to cost-effective improvements in output – in “productivity” – is to ensure that the relationship between input and output is properly balanced. For example, there is little to be gaine...

How to Calculate WIP level in Cutting, Sewing and Finishing Section? Work in progress (WIP) or  in-process inventory includes the set at large of unfinished items for products in a production process. These items are not yet completed but either just being fabricated or waiting in a queue for further processing or in a buffer storage. In garment manufacturing WIP is generally measured in pieces (unit). WIP can be measured  Total pieces loaded in a process minus total pieces out from that process is the WIP of that process. If you only want to calculate current WIP level or how many pieces are there as a WIP in a section use following formula - Cutting Room WIP:  When one calculates cutting room WIP only stock cut pieces is considered as cutting WIP. Fabric those are layered on table or received from fabric store for cutting is not considered as WIP. Cutting WIP = Total cut qty - Total qty sent to sewing, For example, Cutting room cut total 5000 pieces for style# A and 300...