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. 

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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	Over lock machine	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