Category Archives: Garments Technology-IV

Differences between Lean Manufacturing and Traditional Manufacturing


Traditional Manufacturing Lean Manufacturing
No. of equipment and people High Less
Factory space for same output High Less
Work in Progress (WIP) High Less
Defects High Less
Operational availability Less High
Production Lead time High Less
Inventory Inventory is good Inventory is WASTE
System schedule Push system scheduled internally Pull system scheduled by  CustomerRequirements
Focus Focus on Value-Add improvement(5%) Focus on Non-Value-Add WasteElimination (95%)
Direct labor cost High direct labor cost Direct labor cost is a small percentage of total labor cost
Cycle time Long cycle time Short cycle time
Production Production for inventory (Just In Case-JIC) Production on demand (Just In Time-JIT)
Inventory level High inventory levels (Raw, WIP, Finished) Inventory levels are radically reduced.
Production system Assembly line flow (Each worker performs one function) Cell production (Each operator performs multiple operations – multi skilled operators)
Cleanliness Messy, cluttered and dirty shop floor Spotless shop floor with visual management
Quality management Quality management through inspection and rework management of quality through prevention
Changes in production practice Infrequent changes in production practice Continuous changes to improve efficiency and productivity
Management layer Many layers of management Fewer layers of management
structure Not exactly team based structure Strong team based structure.

Critical Path Method and Garmenting


Time consumed in product development (PD) is the biggest issue. Approvals and bulk fabric in-house consumes approximately 75% of the total pre-production activity time and as far the most time-consuming task. Whole supply chain needs a system which

  Reduces time spent in PD.

  Co-ordinates   internally   for all   pre production activity.

  Producing a high quality clear-cut specifications for manufacturing and quality purposes

About 60% of the delays are at pre production stage and remaining at the production stage and reduction of such time can help the  company in meeting the delivery dates on time. Controlling the delay would enable the company to reduce the deviation   from the schedules lead time and honor the delivery date.


  Garment merchandising activities are characterized by people oriented function .

  Interdependent activities are synchronized between succeeding and preceding activities to make process network .

  Critical chain is the solution the garment industry is looking for as it is based on task dependency. Read the rest of this entry

Load and Capacity calculation for garments production planning

For an effective production planning and regarding taking order from buyer, one should know the capacity of his facility and the load what he is going to put. An equilibrium in load and capacity is necessary to fulfill the order in right time and ensure a timely delivery.


Garments Analysis for Production Planning:

  • Garments analysis is very important to make a production schedule or plan.
  • The same time we should have the idea about the operator’s capacity for particular operation so that the specific job will be completed smoothly.

During garments analysis we should check the following points very carefully:

  • Garments observations
  • Key seam quality areas by operation, stitch & seam construction and SPI
  • Point out how many operations are involved in the particular item.
  • Accordingly make a diagram of machine lay out.
  • Point out the critical operation where we can expect the “bottle neck” during production.
  • Considering bottle neck allow extra machines for that operation to keep production flow as you expect.
  • Find out the input operation and out put operation also.

Read the rest of this entry

Time study in Industrial Engineering (RMG)

time study

Time study:

Time study is a work measurement technique for recording the time of performing a certain specific job or its element carried out under specific condition and for analyzing the data so as to obtain the time necessary for an operator to carry out at a defined rate of performance.

Time study is a method of direct observation. A trained observer watches the job and records data as the job is being performed over a number of cycles.

Time study equipment:

The stop watch in general, two types of watch are used for time study.

  1. Fly back
  2. Continuous

Read the rest of this entry

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