How to Setup Machine Layout for Basic Woven Shirt in Clothing Industry?

Woven Shirt Sewing Production Line Layout in Apparel Industry:
Machine layout plan is always a key factor for higher production. If the total plan is executed perfectly then it will easy for the production team to meet shipment date without any hassle. As its importance, this article has presented a well-tested machine layout plan for woven shirt or formal shirt or casual shirt or basic shirt. 

Woven shirt machine layout in apparel industry
Fig: Woven shirt machine layout in apparel industry
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Machine Layout for Woven Shirt in Apparel Manufacturing Sector:

We will make calculations for body and collar-cuffs-sleeves separately @150pc per hour. Body processes operations are shown here. Processes are allocated to operators so as to make a layout for body processes.

Machine Lay Out Plan for Shirt Body:

SL No.
Name of Operations
Machine Required
Standard Time
Operator Allocation
01
Attach top center to left front
4-ndl double chain stitch machine
24”
Operator-1
02
Hem pocket mouth
1-ndl lock stitch with thread trimmer
12”
Operator-2,3
03
Fold pocket
Manual
42”
Operator-4,5
04
Attach pocket
1-ndl lock stitch with thread trimmer
40”
Operator-2,3
05
Hem right front button stand
1-ndl lock stitch with hemmer folder
24”
Operator-6
06
Cut & fold label
Label cutting & folding machine
3”
Operator-7
07
Attach label to under yoke
1-ndl lock stitch with thread trimmer
16”
Operator-7
08
Back yoke attach sewing
1-ndl lock stitch with thread trimmer
24”
Operator-8
09
Back yoke top stitch
1-ndl lock stitch with thread trimmer
19”
Operator-9
10
Shoulder join
1-ndl lock stitch with thread trimmer
46”
Operator-10, 11
11
Top stitch on shoulder join
1-ndl lock stitch with thread trimmer
24”
Operator-12
12
Attach sleeves
2-ndl 5-thread safety stitcher
48”
Operator-13, 14
13
Side seam
2-ndl feed of the arm machine
46”
Operator-15, 16
14
Collar attach sew
1-ndl lock stitch with thread trimmer
40”
Operator-17, 18
15
Collar attach stitch
1-ndl lock stitch with thread trimmer
40”
Operator-19, 20
16
Hem body bottom
1-ndl lock stitch with thread trimmer with hemmer foot
24”
Operator-21
17
Attach cuffs
1-ndl lock stitch with cuff folder
48”
Operator-22, 23
18
Button sewing
Button sewing machine
38”
Operator-24, 25
19
Buttonhole sewing
Buttonhole sewing machine
36”
Operator-26, 27
Total standard time for body processes
594”

Average Process Time Calculation Method:

Average process time,
= (594/19)
= 31.26”

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

Production target per hour with 27 operators,
= {(27×3600×0.85)/594}
= 139pcs per hour

Again,
Bottleneck time= 26 second,

So,
Production per hour,
= (3600/26)
= 138pcs per hour.

Now,

Basic pitch time (BPT) is,
= (594/27)
= 22”

Again,
Upper control limit (UCL) is,
= (22”/0.85)
= 25.88”

Again,
Lower control limit (LCL) is,
= {2 × (BPT-UCL)}
= (44-25.88”)
= 18.12”

Now,
Organization efficiency is,
= (BPT/Bottleneck time)
= {(22”/26”) × 100}
= 84.66%

Again,

Direct productivity is,
= (138/27)
= 5.11 pcs per operator per hour



Machine Lay Out Plan for Shirt Collar, Cuffs and Sleeves:

SL No.
Name of Operations
Machine Required
Standard Time
Operator Allocation
Collar Processes
Fp-1
Fuse interlining
Fusing press
6”
Operator-Fp-1
Clr-2
Sew collar
1-ndl lock stitch with thread trimmer
24”
Operator-1
Clr-3
Cut collar tip & turn
Manual
22”
Operator-2
Clr-4
Form collar
Collar forming machine
20”
Operator-3
Clr-5
Press collar
Manual
20”
Operator-4
Clr-6
Top stitch collar
1-ndl lock stitch with thread trimmer
16”
Operator-5
Clr-7
Sew collar bottom
1-ndl lock stitch with thread trimmer
8”
Operator-5
Clr-8
Trim collar bottom
Collar contour trimmer
6”
Operator-6
Fp-1
Fuse interlining to band
Fusing press
6”
Operator-Fp-1
Clr-9
Feel or roll band
1-ndl lock stitch with thread trimmer
18”
Operator-6
Clr-10
Collar band attach sewing
1-ndl lock stitch with thread trimmer
24”
Operator-7
Clr-11
Turn band
Manual
10”
Operator-8
Clr-12
Collar band attach stitch
1-ndl lock stitch with thread trimmer
18”
Operator-9
Clr-13
Cut band bottom
6v
Operator-9
Clr-14
Mark 3-point on collar
Manual
12”
Operator-8
Cuff Processes
Fp-1
Fuse interlining
Fusing press
12”
Operator-Fp-1
Cf-2
Fell or roll cuff
1-ndl lock stitch with thread trimmer
18”
Operator-10, 11
Cf-3
Sew or run stitch cuffs
1-ndl lock stitch with thread trimmer
30”
Operator-10, 11
Cf-4
Fold inside
Iron or vacuum board
8”
Operator-12
Cf-5
Turn cuffs
Manual or iron
12”
Operator-12
Cf-6
Form cuffs
Cuff forming machine
24”
Operator-13
Cf-7
Top stitch cuffs
1-ndl lock stitch with thread trimmer
18”
Operator-14
Cf-8
Cuff pair match
Manual
6”
Operator-15
Sleeve Processes
Slv-1
Sew under placket to sleeve
1-ndl lock stitch with thread trimmer
18”
Operator-15
Slv-2
Fold upper placket
Manual
24”
Operator-16
Slv-3
Attach sleeve placket
1-ndl lock stitch with thread trimmer
36”
Operator-17, 18
Total standard time for collar, cuff & sleeves
422”

Average Process Time Calculation Method:

Average process time,
= (422/24)
= 17.58”

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

Production target per hour with 19 operators,
= {(19×3600×0.85)/422}
= 143pcs per hour

Again,

Bottleneck time= 24 seconds,

So,

Production per hour is,
= (3600/24)
= 150pcs per hour

Now,

Basic pitch time (BPT) is,
= (422/19)
= 22.21”

Again,
Upper control limit (UCL) is,
= (22.21”/0.85)
= 26.13”

Again,
Lower control limit (LCL) is,
= {2 × (BPT-UCL)}
= (44.42-26.13”)
= 18.29”

Now,

Organization efficiency is,
= (BPT/Bottleneck time)
= {(22.21”/24”) × 100}
= 97.66%

Again,

Direct productivity is,
= (150/18)
= 8.33 pcs per operator per hour