Investigations of the structure and process parameters of sewing operation

• Abstract • Reference • Abstract This paper represents the use of some tools and techniques for improving apparel sewing section efficiency throughout the production process. Now a day's apparel manufacturing industries are trying to develop their current production system and situation and continuously looking for new production tools and techniques in order to keep swiftness with the rapid changes of trend in consumers of apparel products. To deal with the recent problems & challenges industries have to improve production efficiency & productivity; reduce lead time, ensuring proper quality requirements. There is no doubt that sewing section in an apparel industry is the most momentous and teeming department that plays a vital role in the whole firm. To improve the existing situation of this section and increasing productivity time study is a very effective technique. In time study, Standard Minute Value (SMV) has been calculated for each operation or job. Based on this technique each operators capacity is measured and balanced to eliminate the bottlenecks. Here, by applying these techniques significant improvements in the sewing section have been achieved such as SMV, man power, bottle neck, capacity achievable, production/hr, performance rating, balance % and line efficiency. The findings can be extended to similar apparel industries in future. General overviews to these works are presented in this paper.

Bottlenecks in any manufacturing unit are the main causes of reduced efficiency and productivity. Bottleneck can be caused by improper method of performing a particular operation, machinery condition and unnecessary non-value-added time. The major cause of bottleneck in a labor-intensive manufacturing unit is the improper method of performing a operation. Operators create a lot of non-value-added time because of stoppages or preparing for a start-up before actually performing the operation. Sewing a particular part is a sort of start-stop process, where the operator has to frequently start and stop the sewing machine. So, every time the sewing is started, the operator takes some time preparing for the operation, commonly known as burst, which is one of main reasons of non-value-added time. In order to reduce this, time study and motion study are two of the most important and easy to implement tools for improving the efficiency, productivity and method of working. In the present study, time study and motion study were performed on a jacket sewing line and after analyzing the results method improvements were implemented which led to an increase in the productivity of the operators at zero cost.

There is no doubt that sewing section in an apparel industry is the most important department that plays a vital role in the whole firm .Time study is a method of measuring work for recording the time of performing a certain specific task or its elements carried out under specified conditions. To improve the existing situation of this section and increasing productivity, time study is a very effective technique. This study is based on calculations of standard minute value (SMV) of a U3 long sleeve shirt. For conducting time study, a traditional stop watch was used for measuring time of each operation. The U3 shirt (Uniform number 3) manufacturing has 43 operations, for each one 10 measurements were taken for each task and operator working on the line. Then the average of each task is calculated and the final SMV as well.

Journal of Loss Prevention in the Process Industries, 2011

Difficulties in determining the standard time justify the need to develop alternative methods to direct measurement procedures. The indirect methods which are comparison and prediction, standard data and formulation, predefined movement-time systems have several deficiencies in time measurement procedures. In this study, an alternative indirect work measurement method based on artificial neural networks (ANNs) is presented which is simple and inexpensive. For the application of the proposed method, the products that have similar production processes are selected among the whole product family produced in a manufacturing company. The standard times of the sampled products that are previously measured are used and the standard times of the remaining several products and semiproducts are predicted by the proposed method. The model results show that the proposed method can be applied accurately in companies which produce similar products.

Tekstilna industrija, 2019

Quality is the best investment to strengthen the competitiveness of enterprises in the international market. Achieving quality is the responsibility of every worker in the organization. The role of quality control is to detect defects by constantly monitoring the production process, analyzing the defects, fi nd the source of their occurrence and take appropriate corrective measurements. In this paper, are presented some factors that have infl uence on defects occurrence in the process of sewing one model of female trousers. The obtained results during the inter-phase control in two production lines in the four week period are analyzed. Possible reasons for detected defects are indicated by: Working days in the week, the structure of the employees in the production lines, their work experience, their age and diffi culty of operations. The infl uence of each of these factors is discussed separately.

International Journal of Textile Science, 2015

This paper represents the use of some tools and techniques for improving apparel sewing section efficiency throughout the production process. Now a day's apparel manufacturing industries are trying to develop their current production system and situation and continuously looking for new production tools and techniques in order to keep swiftness with the rapid changes of trend in consumers of apparel products. To deal with the recent problems & challenges industries have to improve production efficiency & productivity; reduce lead time, ensuring proper quality requirements. There is no doubt that sewing section in an apparel industry is the most momentous and teeming department that plays a vital role in the whole firm. To improve the existing situation of this section and increasing productivity time study is a very effective technique. In time study, Standard Minute Value (SMV) has been calculated for each operation or job. Based on this technique each operators capacity is measured and balanced to eliminate the bottlenecks. Here, by applying these techniques significant improvements in the sewing section have been achieved such as SMV, man power, bottle neck, capacity achievable, production/hr, performance rating, balance % and line efficiency. The findings can be extended to similar apparel industries in future. General overviews to these works are presented in this paper.

2015

The paper includes a methodology to calculate the fabric laying and cutting times for a cutting department of an apparel manufacturing company. The methodology was developed based on the data collected for woven trouser patterns. A data base of basic times was developed for fabric laying and cutting operations. By analyzing the variations in time values in relation to the parameters that effect the process relationships were developed which were used to calculate the standard minute values for the process. The methodology can be used to calculate the SMV for a lay and it can be further used to develop incentive schemes for the cutting department.

AUTEX Research Journal, 2019

Apparel industry is not only one of the oldest, largest, labor-intensive, and most global industries but also the typical “starter” industry for countries engaged in export-orientated industrialization. To achieve such dreams, the industry has looked over different inter-dependable factors while producing different products. In this study, an effort has been made to establish a correlation between standard allowed minutes (SAMs) and effi ciency of sewing section using different variables, including production rate, number of workstations, and operation breakdown, having a differential impact on both the selected variables. All the empirical analyses were planned in a vertically integrated textile company called Almeda Textile Private Limited Company (PLC), Ethiopia, starting from the basic product category (such as V-neck shirt) up to complicated workwear including military clothing and federal police uniforms of Ethiopia. The Pearson correlation coeffi cient method was chosen to fi nd the relationship between bivariate linearly scaled variables using Statistical Package for Social Science (SPSS) software. The expected outcome will help in identifying the type of correlation and its signifi cant level as well as its impact on the overall productivity of the sewing section which eventually leads to fulfi lling the mission of attaining sustainable production capacity of the mentioned vertically integrated manufacturing company.

2015

This paper presents a summary of the developments in process control in textile processes at the University of Minho, by a multidisciplinary research group involving three different departments (Textile, Electronic and Mechanical Engineering). The studies target the automatic process parameter monitoring and control in the areas of industrial sewing and knitting.

2017

This study is based on proper utilization of man and machine to improve the efficiency and a proper line balancing of a sewing line. In industry sectors, it is important to manufacture the products which have good quality and meet customers’ demand. This act ion could be conducted under existing resources such as employees, machines and other facilities. However, plant layout improvement, could be one of the tools to response to increase industrial productivity. Plant layout design has become a fundamental basis of today’s industrial plants which can influence parts of work efficiency. To increase the efficiency detailed work and time study were performed along the line. In this paper we showed how an effective layout can be designed and efficiency can be increased by appropriate line balancing using time study technique.