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Manufacturing
One prime objective of industrial engineering is to increase
productivity by eliminating waste and non-value adding
operations from the manufacturing process. So it is essential
to know the wastes and non-value adding functions those
exist in garment manufacturing.
1. Transportation
When work is transferred from one place to another is a nonvalue added activity. Moving cuttings from cutting department
to sewing lines, transporting stitched garments from sewing
floor to finishing department, Moving garment bundles in the
line using center table or trolley. Where transportation cant
be eliminated, think how transportation time can be reduced.
2. Excess inventory
Inventories of a factory represents those items which are
either in the process of manufacturing or idle resources
(material) of a factory or materials in stock. And excess
inventory means keeping or generating inventory for the
following process more than the demand of the following
process.
Excess inventory is found in fabric and trim stores, cutting
racks, finishing trolleys. Excess inventories are wastes for the
factory, as per lean philosophy. Inventory is money. When
inventory piled up in stores and on floors, you are blocking
your money and are blocking your working space. Even in a
sewing line excess work-in-process (WIP) are considered as
excess inventory.
3. Excess motion
In workstations where operators sew garments, press-men
press garments, workers finish and pack garments, excess
motions exits there. Excess motion at workstations is found
due to poor training of workers in working methods and habit
of working in traditional ways. In the factories where there are
engineering department to designs workstation layout,
operators may use excess motion due to poor workstation
layout.
4. Waiting
This waste is defined as people or things waiting around for
the next action. This term has been discussed in an earlier
published article as one of the non-productive times in
production.
In garment factory, waiting as waste is found in all processes.
Like, sewing operators wait for cuttings (no feeding),
supervisors waits for final instruction and go ahead for quality
5. Over Production
This waste can be simply defined as doing or making things
those are not required now. Over production generate excess
inventory. In the garment factories, over production is found in
cutting department and in sewing operations. For example, if
daily production demand from sewing is 5000 pieces, and
factory makes/cuts more than that that quantity (demand),
factory is producing excess units of garments than needed by
the following process for the day (finishing). Over-production
cause imbalance in work in process (WIP).
6. Over processing
This waste can be defined as doing task or adding features to
the product those are not requirement from the customer. In
garment construction, some operations may not be essential
to give the final look and construction. Example: Multiple
checking in finishing (initial checking, pre-final checking and
final checking).
7. Defects
Producing defects while making garments are waste of money
and effort. As everyone in the factory are aware that no
defective garment can be shipped then why to produce
defective pieces? Defects in garment manufacturing are like
shade variation, wrong cutting, stitching defective garment
etc. In case defective garments are made, factory needs to
alter and repair those defective garments before handing over
to the buyer. Repair work costs money and time. In lean
manufacturing factories aim to produce garments right first
time. For different types of defects found in garments read
this article.
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Garment manufacturing includes number of processes from
order receiving to dispatching shipment of the finished
garments. A process flow chart helps to understand how raw
materials are moved from one process to another process
until raw materials are transformed into the desired product
(garments).
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You need to find out target production of a line everyday. You
can get the information from your IE but you can also
estimate it yourself just having knowledge of few figures. The
scientific way of planning daily production or line output is to
calculate estimated production from garment SAM.
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Question: What are the main tasks (process or steps) of
production planning in garment manufacturing? How one can
easily make production plan for woven factory? ...asked by
Arif Hossain
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Planning Board.
Click on the image to Zoom.
Read our previous post for line loading plan. How to make line
loading plan?
#3 Calculations: First calculate capacity requirement for the
order you are going to plan. Secondly, check capacity
availability in all processes on the given time frame.
Line capacity can be also calculated in minutes. For example,
a garment SAM is 30 minutes and line performs at 50%
efficiency. Calculate total capacity required (man hours) to
complete sewing on time.