Machine Work Study in Garment Manufacturing Factories

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Why Machine Work Study?

Improvement Possibilities  - "Replacement of Machines Opportunity" to  "Work Aids Provision" and "Incremental Machine Level Automation"

Automatic machines are now available for replacing currently used machines. Do replacement analysis. Replacement analysis is industrial engineering. It is specially taught in IE Engineering Analysis.

Highlighted case study

Improving Productivity by Using Extra Mechanical Automation on Different Sewing Machine. Interesting case study.

One machine was changed. Automation increased on some machine. Due to these machine related changes, manpower was reduced from 70 to 62 in this line.

http://article.sapub.org/10.5923.j.textile.20190801.04.html

______________________

https://www.youtube.com/watch?v=b31oEBYu-T4

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Some machines used in garment production

1. Single needle lock stitch

2. Double needle lock stitch .

3. Chain stitch machines ,

4. Over lock machines .

5. Multi needle chain stitch machines.

6. Feed of the arm machine .

7. Button stitch machine.

8. Button hole Machine .

About Machines

Single needle lock stitch

https://www.juki.co.jp/industrial_e/products_e/apparel_e/1needle_lock_e/

https://oaltd.com.ng/product/ism/JK0303

Double needle lock stitch .

https://www.sakura-stitch.com/index.php/product/view/high-speed-double-needle-lockstitch-machine

https://industrialsewingmachine.global.brother/en-emea/twin_lock/t8422d/index.aspx

https://www.hobkirk.co.uk/zoje-sewing-machines-lockstitch-2-needle

Many machines list

https://magnumresources.co.in/products/

Chain stitch machine

https://www.duerkopp-adler.com/en/main/products/MS_04_chainstitch/

https://www.duerkopp-adler.com/en/main/products/MS_04_chainstitch/195-171120-01.html

https://www.serasewing.net/single-double-three-needle-chain-stitch-machine-2618933.html

Ironing Machine 

Model: YPS-006

Double Body Shirt Automated Ironing Machine 

- Works On Solar

- Productivity: 240 Shirts / Hr

Model: YPS-503

Quadruple Collar and Cuff Automatic Ironing Machine

- Productivity: 240 shirts / Hr

https://yacjapan.in/automatic-ironing-machine.html

Benefits Of Using Knitted Fabric Inspection Machines

B-TEX TEXTILE MACHINERY

304, 3rd Floor, Vikas Centre,

Dr. C. G. Road, Chembur (E),

Mumbai - 400 074, Maharashtra, India.

 +91 -22-6573 3405 / 6671 2272

Mobile No.:9820474553

 sales@btexindia.com

https://www.btexindia.com/a-study-on-knitted-fabric-inspection-in-textile-and-apparel-industry/

________________

https://www.youtube.com/watch?v=0Bf6cq9-YU4

________________

Sweater Manufacturing Process

https://onlinesweaterstudy.blogspot.com/2021/10/sweater-manufacturing-process-to-z-flow.html

https://www.academia.edu/32732741/Project_on_Comparative_Analysis_for_Manufacturing_A_Fully_Fashioned_Sweater

________________

https://www.youtube.com/watch?v=uxbNvERXRYo

________________

https://www.cottonworks.com/en/topics/sourcing-manufacturing/sweater-manufacturing/sweater-manufacturing-basics/

"Sweater production process" has many results in google search.

Difference between Single Jersey and Interlock Circular Knitting Machine

30/05/2022 by textileblog

Single Jersey Circular Knitting Machine:

Single jersey circular knitting machine is the most used knitting machine in textile knitting industry. Latch needle, cylinder and sinker ring revolve through the stationary knitting cam systems

Interlock Circular Knitting Machine:

Interlock circular knitting machine is also a very commonly used machine in country to make interlock knitted fabric. The machine has two sets of needles on two different beds, one set on cylinder one in the dial bed

https://www.textileblog.com/single-jersey-and-interlock-circular-knitting-machine/

Productivity in Garment Production

2021

Implementation of an Automated Manufacturing Process for Smart Clothing: The Case Study of a Smart Sports Bra

Processes 2021, 9, 289., https://doi.org/10.3390/pr9020289

Processes

Design

Patternmaking

Embroidery

Automated cutting

Pick and Place by Robot

Automatic Sewing

In this study, the KITECH logo was designed over the sports bra pattern using technical embroidery techniques. embroidery techniques. For this, a technical embroidery machine (SGVA 0109-825, ZSK Stickmaschinen, Krefeld, Germany) was used.

Automatic cutting machines can cut single or multiple plies of a wide variety of fabrics, from lightweight apparel fabric to high-performance industrial fabrics. Cutting can be performed using a laser, knife, or water-jet. The advantages of automatic cutting are the increased efficiency and accuracy, ease of cutting single and multiple plies, and perfect cutting the first time.

In this study, several embroidered fabrics were placed on the automatic cutting machine (P-CAM 161, Shima Seiki, Wakayama, Japan) for cutting into the patterns. For matching the embroidered logo on the accurate position, a full-size pattern piece was projected on the fabric as it was spread over the cutting surface using an overhead projector.

Robot Handling with a Gripping System

As a result, an electric needle gripper (SNGi-AE, Schmalz, Glatten, Germany), which can electrically adjust the length of the edle stroke, was chosen for this study; It showed robust performance for numerous fabric types without noticeable damage. 

Automatic Sewing

In this study, two tasks were performed to realize automatic sewing technology. First, an automatic feeding system was developed to develop an automatic sewing process using a motor and acceleration sensor. The automatic feeding system was located on the right side of the industrial pattern sewing machine (ASM-224, JUKI, Tokyo, Japan), as shown in Figure 21a, and was designed to move the cut material to the sewing position. Two templates were then produced, as shown in Figure 21b. Each was placed above and below the pattern that will be sewn to be moved using an automatic feeding system. The template was designed using two polycarbonate materials by drilling two shoulder lines and two

lines next to the bust sewn 15 mm thick.

https://www.mdpi.com/2227-9717/9/2/289/pdf

https://tukatech.com/garment-manufacturing-machine/   Many case studies provided.

Asher Fabric Concepts Use of TukaTech Machines

__________________

https://www.youtube.com/watch?v=m3sZRxUyWMc

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https://guidingmetrics.com/content/key-apparel-industry-metrics/

https://archive.ics.uci.edu/ml/datasets/Productivity+Prediction+of+Garment+Employees

https://www.juki.co.jp/en/company/our-business/industrial-business/

https://garment.io/

https://garmentsmerchandising.com/how-to-estimate-line-efficiency-of-garment-production/

https://www.iigm.in/Industries/Apparel/Automation/Stackers/Br

https://textilevaluechain.in/in-depth-analysis/articles/textile-articles/automation-in-apparel-industry/

https://www.coatsdigital.com/7-tips-for-better-cutting-room-productivity/

https://www.epaakin.com/about

2020

9 Excellent Robot Applications in the Textile Industry

https://robodk.com/blog/robot-applications-textile-industry/

Automated Cutting & Sewing Developments

March 26, 2020

The most recent ITMA highlighted trends in cutting and sewing automation.

By Dr. Minyoung Suh

https://www.textileworld.com/textile-world/features/2020/03/automated-cutting-sewing-developments/

https://fashive.org/how-is-automation-reshaping-garment-manufacturing/

https://www.fibre2fashion.com/industry-article/8690/improving-apparel-production-through-intelligent-sewing-machines

https://www.textileblog.com/efficiency-and-productivity-of-sewing-line/

https://www.wastra.in/harnessing-productivity-in-the-indian-apparel-industry

https://www.speedstepsoftware.com/news/blog/236-common-problems-found-in-garment-production

2019

Robotic 3D Garment Assembly and Automatic Material Handling. Is it Feasible? 

Philipp Moll, Ulla Schütte, Kerstin Zöll

https://www.researchgate.net/publication/233895854_Automated_Garment_Assembly_and_Manufacturing_Simulation

Machines Used for Garment Manufacturing

Hall Harris

Updated January 25, 2019

https://smallbusiness.chron.com/machines-used-garment-manufacturing-77517.html

https://www.logicerp.com/blog/2019/03/26/how-can-apparel-erp-software-help-manufacturers-boost-productivity/

https://onlinegarmentsacademy.blogspot.com/2019/05/breakdown-preventive-maintenance-Garments-sewing-machine.html

https://irispublishers.com/jtsft/fulltext/improvement-of-efficiency-and-productivity-through-machine-balancing-in-a-sewing-line.ID.000541.php

https://medcraveonline.com/JTEFT/high-tech-machine-in-rmg-industry-reducing-smv-lead-time-and-boosting-up-the-productivity.html

Improving Productivity by Using Extra Mechanical Automation on Different Sewing Machine. Interesting case study.

One machine was changed. Automation increased on some machine. Due to these machine related changes, manpower was reduced from 70 to 62 in this line.

http://article.sapub.org/10.5923.j.textile.20190801.04.html

Which industrial sewing machine gives you the greatest productivity?

May 20, 2019

https://industrial-sewingmachine.com/which-industrial-sewing-machines-gives-you-the-greatest-productivity/

https://www.textileschool.com/193/garment-production-process/

2018

Increasing the productivity and efficiency of a sewing line in an apparel manufacturing industry by using working aids

Thesis/ project worked on increased the efficiency & productivity of a sewing line by using working aids

May. 01, 2018

https://www.slideshare.net/MazedulIslamSoyeb/increasing-the-productivity-and-efficiency-of-a-sewing-line-in-an-apparel-manufacturing-industry-by-using-working-aids

SewBot Is Revolutionizing the Clothing Manufacturing Industry

FEBRUARY 19, 2018

In Bangladesh the labor cost to produce a denim shirt is about $0.22. If made by U.S. workers, that labor cost jumps to $7.47, but with a robotic production line, it’s just $0.33 per t-shirt.

https://www.deviceplus.com/trending/sewbot-in-the-clothing-manufacturing-industry/

Use Work Aids

Work aids are Additional devices that can be added to basic sewing machines such as folders, guides, and pressure feet. If work aids are used effectively operation cycle time can be reduced many folds than existing cycle time.

https://ordnur.com/textile/productivity-improvement-techniques-in-apparel-manufacturing-industry/

https://www.linkedin.com/pulse/unorganized-organized-improve-productivity-garment-factory-yakeem-1e/

2017

Automated Apparel Machinery & Equipment Essential to Competitive Advantage

By: David Russell Schilling

April 9th, 2017

https://www.industrytap.com/automated-apparel-machinery-equipment-essential-competitive-advantage/41814

2016

https://www.cgsinc.com/blog/lean-manufacturing-garment-industry-apparel-business

https://www.onlineclothingstudy.com/2016/09/how-to-calculate-machine-productivity.html

2011

https://www.intechopen.com/books/assembly-line-theory-and-practice/model-sequencing-andassembly-line-balancing-in-garment-production-by-simulation-worker-transfer-syst

https://www.britannica.com/topic/clothing-and-footwear-industry/Modern-manufacturing-processes-and-equipment

2012

https://www.academia.edu/33142141/Ways_to_Increase_Sewing_Operator_Efficiency

2006

 Garment production systems: An overview

https://www.indiantextilejournal.com/articles/fadetails.asp?id=28

PDF Files Related to Garment Manufacturing Machines and Productivity

https://www.researchgate.net/publication/332752150_Improvement_of_Efficiency_and_Productivity_Through_Machine_Balancing_in_a_Sewing_Line

https://www.researchgate.net/publication/322656789_Improving_Productivity_of_Garment_Industry_with_Time_Study

https://www.ilo.org/wcmsp5/groups/public/---ed_protect/---protrav/---safework/documents/instructionalmaterial/wcms_228220.pdf

https://globaljournals.org/GJRE_Volume18/5-Increase-the-Efficiency.pdf

http://engineering-shirpur.nmims.edu/docs/enhancing-efficiency-and-productivity-of-garment-industry-by-using-different-techniques.pdf

https://www.econstor.eu/bitstream/10419/187328/1/pidsdps9709.pdf

http://ncert.nic.in/textbook/pdf/lehe203.pdf

http://lib.buet.ac.bd:8080/xmlui/bitstream/handle/123456789/3803/Full%20Thesis.pdf?sequence=1

https://textiles.ncsu.edu/tatm/wp-content/uploads/sites/4/2017/11/bheda_full-1.pdf

https://textiles.ncsu.edu/tatm/wp-content/uploads/sites/4/2017/11/bheda_full-1.pdf

https://www.ijert.org/research/productivity-improvement-through-lean-manufacturing-tools-a-case-study-on-ethiopian-garment-industry-IJERTV3IS090977.pdf

https://www.hilarispublisher.com/open-access/analysis-on-production-efficiency-of-lean-implemented-sewing-line-a-case-study-2165-8064-1000386.pdf

https://www.academia.edu/33547012/PRODUCTION_LINE_BALANCING_FOR_PRODUCTIVITY_IMPROVEMENT_IN_APPAREL_MANUFACTURING_Supervised_by_Submitted_by

http://www.deginvest.de/DEG-Documents-in-English/About-DEG/What-is-our-impact/Case_Study_JMS_Holding_Ltd_Web.pdf

https://www.emerald.com/insight/content/doi/10.1108/09556229410054477/full/pdf

http://www.axseum.com/journal/pages/61a086-types-of-sewing-machine-in-garment-industry-pdf

https://www.ijser.org/researchpaper/Effect-of-time-and-motion-study-on-productivity-in-garment-sector.pdf

http://ijimt.org/papers/137-M568.pdf

http://etd.aau.edu.et/bitstream/handle/123456789/20369/Henok%20Tamirat%20.pdf?sequence=1&isAllowed=y

https://core.ac.uk/download/pdf/236413468.pdf

http://www.iitg.ac.in/aimtdr2014/PROCEEDINGS/papers/552.pdf

https://iopscience.iop.org/article/10.1088/1757-899X/1059/1/012027/pdf

http://www.ieomsociety.org/ieom2019/papers/413.pdf

https://www.icrier.org/pdf/wp147.pdf

https://www.ijeat.org/wp-content/uploads/papers/v7i4/D5328047418.pdf

http://www.kuet.ac.bd/webportal/ppmv2/uploads/1493791458EJAET-3-3-30-36.pdf

https://www.kviconline.gov.in/pmegp/pmegpweb/docs/commonprojectprofile/PROJECT%20PROFILE%20ON%20GENT'S%20SHIRTS.pdf

http://www.academicjournal.in/download/456/2-4-23-587.pdf

http://www.ijecs.in/index.php/ijecs/article/download/4503/3962/8918

https://www.eajournals.org/wp-content/uploads/Implementation-of-Modern-Garment-Planning-Tools-Techniques-in-Garment-Industry-of-Bangladesh.pdf

https://data.opendevelopmentmekong.net/dataset/a95f3eb1-263b-4605-a896-21c620459560/resource/63da8a56-8c42-446e-9661-0a1742d373d5/download/measuring-competitiveness-productivity-cambodia-garment-industry.pdf

https://www.thaiscience.info/journals/Article/TJKM/10470179.pdf

http://www.aepcindia.com/pdfs/Study%20on%20Vietnam%20Apparel%20Industry.pdf

https://www.acmfn.com/wp-content/uploads/2015/09/SMART-Myanmar-Garment-Factories-Improvement-Program.pdf

https://www.intechopen.com/books/textile-manufacturing-processes/introductory-chapter-textile-manufacturing-processes

http://iieom.org/paper/133%20rezaul.pdf

https://www.ijset.net/journal/212.pdf

https://journals.sagepub.com/doi/pdf/10.1177/002795018912800104

http://admin.umt.edu.pk/Media/Site/STD1/FileManager/OsamaArticle/january/2_9.pdf

http://shodhbhagirathi.iitr.ac.in:8081/jspui/handle/123456789/243

http://eaas-journal.org/survey/userfiles/files/Minimization%20of%20Reworks%20in%20the%20apparel%20industry.pdf

https://assets.publishing.service.gov.uk/media/5977616f40f0b649a7000022/Skills_productivity_and_employment.pdf

https://pubdocs.worldbank.org/en/710091527997196820/68-Textile-Garment-Productivity-Tekleselassie-et-al-ABCA2018-Final.pdf

https://ijsre.in/Vol-1/Issue-3/26.pdf

https://www.ajol.info/index.php/jfecs/article/view/97501/86808

https://cdn-cms.f-static.net/uploads/4381962/normal_5f8dfab530962.pdf

https://juniperpublishers.com/ctftte/pdf/CTFTTE.MS.ID.555628.pdf

https://citeseerx.ist.psu.edu/viewdoc/download?doi=10.1.1.826.9649&rep=rep1&type=pdf

https://www.adb.org/sites/default/files/publication/183908/sawp-043.pdf

https://www.usitc.gov/publications/332/PUB3401.pdf

https://clri.org/docs/TSV_2035.pdf

http://ijaret.com/wp-content/themes/felicity/issues/vol4issue2/parthraj.pdf

https://www.hrpub.org/download/20141201/MST1-15402913.pdf

https://www.ibef.org/download/Textiles_Apparel_220708.pdf

http://www.fibtex.lodz.pl/pliki/Fibtex_(kxnrjx39rnnionr3).pdf

http://mail.meiji.co.id/cgi-bin/read.php?article=apparel+production+management+technical+package+pdf&code=f4ec75dc79ab38a38d89586d11082e91

https://repositorio.cepal.org/bitstream/handle/11362/29030/S5100163_en.pdf

https://www.mckinsey.com/~/media/mckinsey/industries/retail/our%20insights/is%20apparel%20manufacturing%20coming%20home/is-apparel-manufacturing-coming-home_vf.pdf

http://www.diva-portal.org/smash/get/diva2:1312261/FULLTEXT01.pdf

https://d2hawiim0tjbd8.cloudfront.net/downloads/wwf_guideline_cleaner_production_textile_2018.pdf

https://www.slideshare.net/1416ankur/capacity-planning-in-garment-industry22-3-files-merged

https://www.energystar.gov/sites/default/files/buildings/tools/EE_Guidebook_for_Textile_industry.pdf

http://www.ijtef.org/papers/321-B10013.pdf

https://www.impacteconomy.com/papers/IE_PRIMER_DECEMBER2013_EN.pdf

https://www.iosrjournals.org/iosr-jpte/papers/Vol3-issue2/A03020118.pdf

https://www.bsr.org/reports/BSR_Womens_Empowerment_Africa_Apparel_Brief.pdf

http://www.ijirae.com/volumes/Vol4/iss12/02.DCAE10082.pdf

http://www.eria.org/ERIA-DP-2015-12.pdf

http://www.blinkprods.com/cgi-bin/file.php?article=sewing-for-the-apparel-industry-nd-edition-ebook-claire-shaeffer-pdf&code=ce57269e4340c342ce8308d1dac79175

https://www.europarl.europa.eu/RegData/etudes/BRIE/2019/633143/EPRS_BRI(2019)633143_EN.pdf

https://www.ellenmacarthurfoundation.org/assets/downloads/publications/A-New-Textiles-Economy_Full-Report.pdf

http://www.ijirset.com/upload/2015/july/97_Development.pdf

http://www.managementgeneral.ro/pdf/1_2017_4.pdf

http://www.journal-aprie.com/article_54267_7fd87a9d5bccb2e1c0afdae08e6618b7.pdf

http://cividep.org/wp-content/uploads/2017/04/25-2-Occupational-health-safety-13.pdf

http://www.msmedikanpur.gov.in/cmdatahien/projprof/Gents%20Casual%20Shirts.pdf

https://vetfgc.edu.in/downloads/ict-learning/ambily.pdf

http://en.afborgen.se/cgi-bin/open.php?article=garment%20finishing%20in%20industrial%20engineering%20pdf&code=cd6fe6a79a759d2f6602df7c26727aea

http://www.apjmr.com/wp-content/uploads/2015/11/APJMR-2015-3.4.5.07.pdf

https://www.wto.org/english/tratop_e/devel_e/a4t_e/global_review13prog_e/textles_and_apparel_28june.pdf

https://www.qjie.ir/article_676311_faed46120b515d65d1775094a2906fab.pdf

https://www.monash.edu/__data/assets/pdf_file/0003/925572/duality_in_an_industry_with_fluctuating_demand.pdf

https://www.nber.org/papers/w24314.pdf

https://ir.bdu.edu.et/bitstream/handle/123456789/8270/to%20library.pdf?sequence=1&isAllowed=y

http://texmin.nic.in/sites/default/files/Garment%20Study%20-%20Final%20Report%20-%2026.02.2018.pdf

More Information on Garment Machines

Machines with Atlas

Into Home textiles for about 42 years

Working space 400,000 sq.ft / 40,000 sq.m

100% Cotton, Linen, Polyester Blend, Flex...

Table Linens, Kitchen Linens, Cushion, Curtain, Nursery...

IN-HOUSE FACILITIES

Automatic Rotary Printing Machine (MHMS 12 Color) - 40,000m per day

Vamatex Leonardo Dobby Looms - 200,000m/month

Sulzer Projectile Looms - 225,000m/ month

Single Needle Sewing Machines - 450

Fong's Cone Dyeing Machine

CPB - Fabric / Piece Dyeing - 40,000m per day

Hydraulic Jiggers - 30,000 m/day

Shrinking Range Machine - 30,000 m/day

Computerized Quilting & Embroidery Machines

Bullmer Automatic Spreader/Cutter

Automation for kitchen towels, aprons & gloves with length slit, length hemming, cross cutting and pattern taker machines.

https://atlas.in/atlas-processing-mills/

List of Apparel Machinery with Specifications and Functions:

SL No.

Name of Machine

(Company Name)

Function of Machine

Remarks

01

Hand or paddle sewing machine

(Butterfly, China)

Sewing the garments

02

Industrial single needle lock stitch machine (Taking, China)

Sewing all types of fabric)

03

2-Needle plain sewing machine

(Sunsir, China)

Sewing the garments

04

Flatlock sewing machine

(Taking, China)

Used to sew knit fabric

05

High-speed 2-Needle 5-Thread overlock machine (Taking, China)

Lock the end of fabric by sewing

06

Overlock machine (Juki, Japan)

Secure edge of garments

07

Button stitch machine

(Consew, Japan)

Attach the button with garments

08

A leather cutting (Taking, China)

To cut leather

09

Embroidery machine

(Consew, Japan)

Produce design with the help of a thread on the fabric surface

10

Bar taking machine (Taking, China)

Making a loop in the pant

11

Kansai special machine (Hoseki, China)

Attach elastic to

jacket or coat)

12

Buttonhole machine (Taking, China)

Produce hole in the fabric for button attaching

13

Snap button machine (TK-Super, China)

Manually attach repeat

button

14

Dematic machine

(Butterfly, China)

Sewing the fabric at specific design using different dick

15

Rib cutter

Cut off rib of knit garments

16

Collar turning and blocking machine (NGAI SHING, China)

Used for collar finishing

17

Fusing machine (Shanghai jieshi

clothing machine co. ltd., China)

Used for finishing collar lining

18

Computerized embroidery machine (Hoseki, China)

Making design with thread by using computer

19

Band knife cutting machine

(Oshima, China)

Used to cut off the fabric at a small size

20

Fashion Maker Desmatic machine (Singer, China)

Sewing the fabric at specific design using different disk

21

Straight knife cutting machine

(FJM Dalian, China)

Used to cut off the fabric

Automation in Garment Manufacturing

Intelligent Automation in Shirt Making

by Roberto Inglesi 01-January-2009 

https://apparelresources.com/technology-news/manufacturing-tech/intelligent-automation-in-shirt-making/

Maica Full Automatic Line For Shirt Manufacturing - Sri Lanka

19 Sept 2015

Maquitalia

Full automatic line in Sri Lankan factory producing 50k shirts per day! UAM01, UAM02, UAM03, UAM04 + all other semi automatic units!

https://www.youtube.com/watch?v=bclBH1o84Tk

PORTUGAL

Maica Full Automatic Production Line for Shirt - Portugal

19 Sept 2015

Maquitalia

Overview of Zara factory in Portugal, complete automatic line for 2500 shirts per day!!!

https://www.youtube.com/watch?v=sv536cciOiQ

Automatic Trouser Making

MACPI 320 – Automatic Four Station Unit for Trouser finishing

https://magnumresources.co.in/products/macpi-320-automatic-four-station-unit-for-trouser-finishing/

Trouser Automations

http://www.new-tech.com.tr/en/our-products/trouser-automations

Updated on 30.5.2022,  9.4.2022, 8.4.2022,  26 Dec 2021,  28 June 2021

Published 29 May 2021