How to Setup Machine Lay Out for Jeans Pant in Apparel Industry?

Denim Jeans Manufacturing Process in Apparel Sector:
Jeans is one of the most used apparel for all types of people in today’s fashionable era. To make the targeted number of denim jeans in a limited time we have to follow a correct machine layout. Otherwise we may fail to achieve our targeted jeans production. As its important ace, this article has presented the actual machine layout plan for denim jeans production.

You may follow:
Machine layout for jeans pant manufacturing
Fig: Sewing machine layout for jeans pant manufacturing
Machine Lay Out for Denim Jeans Pant Manufacturing in Clothing Sector:
In order to make a layout plan, let us allocate processes to operators @24” to each sewing operator so as to reach a production capacity of 150pcs per hour.
SL No.
Name of Operations
Machine Required
Standard Time
Operator Allocation
01
Hem watch pocket mouth
1-ndl lock stitch with thread trimmer
7”
Operator-1
02
Fold watch pocket
Manual
24”
Operator-2
03
Attach watch pocket
1-ndl lock stitch with thread trimmer
16”
Operator-1
04
Att. Side pocket facing to pocket bag
1-ndl lock stitch with thread trimmer
24”
Operator-3
05
Close side pocket bag
2-ndl 5 thread safety stitcher
18”
Operator-4
06
Att. Side pocket bag to right front
1-ndl lock stitch with thread trimmer
18”
Operator-5
07
Att. Side pocket facing to pocket bag
1-ndl lock stitch with thread trimmer
24”
Operator-6
08
Close left side pocket bag
2-ndl 5 thread safety stitcher
18”
Operator-7
09
Att. Side pocket bag to left front
1-ndl lock stitch with thread trimmer
18”
Operator-8
10
Att. Zipper to right front fly
1-ndl over lock machine
6”
Operator-9
11
Serge left front
1-ndl over lock machine
6”
Operator-9
12
Attach left front fly
1-ndl lock stitch with thread trimmer
12”
Operator-9
13
Counter stitch left from fly
1-ndl lock stitch with thread trimmer
20”
Operator-10
14
Top stitch pocket mouth
2-ndl lock stitch with thread trimmer
20”
Operator-11
15
Top stitch left front fly
2-ndl lock stitch with thread trimmer
10”
Operator-12
16
Top stitch right front fly
2-ndl lock stitch with thread trimmer
10”
Operator-12
17
Cut & fold care label
Auto label cutting & folding m/c
3”
Operator-12
18
Baste pocket bag top
1-ndl lock stitch with thread trimmer
38”
Operator-13, 14
19
Top stitch crotch
2-ndl lock stitch with thread trimmer
24”
Operator-15
20
Bar tack front fly
Bar tack machine
18”
Operator-16
21
Attach yoke to back
Flatbd dbl. chain stitch machine
18”
Operator-17
22
Hem hip pocket mouth
1-ndl lock stitch with thread trimmer
24”
Operator-18
23
Decorative stitch to hip pocket
1-ndl lock stitch with thread trimmer
48”
Operator-19, 20
24
Fold hip pocket
Pocket folding machine
24”
Operator-21
25
Attach hip pocket to back
1-ndl lock stitch with thread trimmer
48”
Operator-22, 23
26
Bar tack hip pocket edge
Bar tack machine
24”
Operator-24
27
Seat seam
Feed of the arm dbl. chain stitch machine
24”
Operator-25
28
Side seam
Feed of the arm dbl. chain stitch machine
40”
Operator-26, 27
29
Inside seam
2-ndl 5 thread safety stitcher
38”
Operator-28, 29
30
Attach waistband
Flatbd dbl. chain stitch machine
38”
Operator-30, 31
31
Cut & fold waistband corner
Manual
12”
Operator-32
32
Top stitch waistband corner
1-ndl lock stitch with thread trimmer
38”
Operator-33, 34
33
Make belt loops (5pcs)
2-ndl bottom cover stitch machine
6”
Operator-32
34
Attach belt loops
Bar tack machine
69”
Operator-35, 36, 37
35
Att. Leathered label to waistband
1-ndl lock stitch with thread trimmer
18”
Operator-38
36
Hem bottom
1-ndl lock stitch with thread trimmer
40”
Operator-39, 40
37
Sew eyelet buttonhole
Eyelet buttonhole sewing machine
10”
Operator-41
38
Attach metal button
Metal button fastening machine
10”
Operator-41
39
Attach rivet
Riveter
25”
Operator-42
Total standard time
892”
Average Process Time Calculation:

Average process time,
 = (892/39)
 = 22.87”

Calculation of BPT, UCL, LCL, Organization Efficiency & Production Target Per Hour:

Production target per hour with 42 sewing operators,
= {(42×3600×0.85)/892}
= 144pcs per hour

Again,
Bottleneck time= 24 second,

So,

Production per hour stands at,
= (3600/24)
= 150pcs per hour.

Now,
Basic pitch time (BPT) is,
= (892/42)
= 21.23”

Again,
Upper control limit (UCL) stands at,
= (21.23”/0.85)
= 24.97”

Again,
Lower control limit (LCL) stands at,
= {2 × (BPT-UCL)}
= (42.46-24.97”)
= 17.49”

Now,
Organization efficient stands at,
= (BPT/Bottleneck time)
= {(21.23”/24”) × 100}
= 88.45%

Again,
Direct productivity stands at,
= (150/42)
= 3.57 pcs per operator per hour