How to develop the Garments production Line Efficiency & Productivity

The master keys to developing the Garments production Line Efficiency & Productivity

Today I am going to show the Legend tools of developing garments Productivity. Before the start, we know that The RMG industries are constantly imparting the single source of growth in Bangladesh’s hastily developing economic system. Because of being technologically exertions established, it has a huge wide variety of worker involvement, and a maximum of them are lady workers, so it helps in socio-economical improvement of poverty- a fraction of the population of the united states. Day by day increases production costs. The RMG industries are getting very aggressive to draw famous customers and in these days’ competitive. Go to start to develop the Garments production Line Efficiency & Productivity.

the producers especially want to be concerned approximately time, fee, exceptional, and shipping. It is plain that assembling apparel is a relatively laborious technique wherein an excellent quantity of humans take part. But it’s miles a matter of attention that all the labor’s performance and functionality are not equal. So capability version happens very regularly as running ability differs from guy to man. As a result, the manufacturing gadget regularly receives very elaborately to make sure its smoothness. In the case of strolling the clean production, from time to time some operators had been highlighted because of the low performers who are producing less in addition to growing problems for the others.

Pushing system to Pull System

Pushing is the old culture of apparel production to improve productivity. It is not an authentic way to enhance line performance. The old pushing system is the forced method that is harmful for quality and equality.  It is one of the three major components of a complete just-in-time production system. A pull system is a Lean technique for reducing the waste of any production process. Applying a pull system enables you to begin new work just when there is a client interest in it. This offers you the chance to diminish overhead and streamline stockpiling costs.

By applying the pull system you will get the advantages:

  • Meet actual demand
  • Increase productivity and flow efficiency
  • Eliminate waste activities
  • Optimize cost-efficiency

Layout Of the Production Line

The sewing line design is where sewing workstations are set on the sewing floor to shape a line that chips away at a solitary style. Materials start spilling out of the back to the front in the constant requests. All part sub-congregations are begun at the correct time to be prepared at the necessary time and continued moving until the completed item is accessible toward the finish of the sequential construction system. The line to be trailed by the item during movement might be straight, U-formed, round or crisscross and the machines lay in the request in which they are to be utilized.

Workstation Design


Workstation Design is the most common course of action of the necessary things in a predefined route at an assigned territory where explicit occupations or employments are performed. To do the tasks inside the least conceivable time, their dealing with development should be the base. The parts need to put inside the closest hand separation to the administrators so they can pick them just. In the attire business, a perfect workstation format should comprise of least picking and transfer region, least developments and a base length of each activity.

Generate Multiskilled Operator

This is the time of self-freedom. So any operator can keep his right to leave a couple of days. So we need an alternative operator. Who is able to complete 3 to 6 operations. That is the treatment of bottleneck and absenteeism functionality.

Hourly Production Monitoring 

Continue to monitor 15 minutes, hourly and daily production. It will help you to take the necessary action.

The bottleneck operations

In an apparel sewing line, where supply accumulated, production goes under capacity and bunches of Increase the Efficiency and Productivity of Sewing Section Through Low Performing Operators Improvement by utilizing eight Wastes of Lean Methodology in Engineering article of clothing’s parts on explicit workstation stay unattached, those regions are named as bottleneck regions and which fills in as a limitation for smooth progression of production is named as bottleneck.

Effective Line Balancing

The complete work to be performed at a workstation is equivalent to the aggregate of the errands allocated to the workstation. Adjusting the line implies employments doled out to the workstations in a predetermined manner with the goal that every workstation has close to should be possible in the workstation cycle time, thus that unassigned (inactive) time overall workstations limits. In a decent line, materials will stream easily and no time will be lost in hanging tight for work. A suitable adjusting of a sewing line relies upon the component of the work cell plan and it should be connected with different choices to work well.


Productivity is the degree of output in keeping with a unit of input. In the garments stitching section, the operation breakdown of a garment includes numerous lengthy, medium and quick operations and operators additionally allotted on the ones unique operations based totally on their performance and grade. Generally, essential methods are sorted by way of grade – A operators at the same time as semicritical by using grade – B and the grade – C operators appointed to other types of work. The productivity of them can be measured by using how they’re the use of their allotted sources in a worthwhile way e. G. Time, strength, ability, and many others. To gain hooked up goals based totally on the connection between inputs and outputs. If operators don’t make the first-rate possible use of those assets skillfully and wisely, they can’t get the results and accordingly line’s overall production and efficiency will fall. So, productiveness improvement of person operators may be very superior.

Time Study or Work Measurement

Time study and work measurement, both techniques, and tools for estimating work for recording the times of achieving explicit errands or its components completed under determined conditions. An administrator does the same activity for the duration of the day. Time study characterizes how much time is vital for an administrator to complete the activity at a characterized pace of execution. The point of time study is to set up a time for a certified laborer to do positive work under-expressed conditions and at an expressed measure of working. Read

SMV (Standard Minute Value) 

SMV represents Standard Minute Value, which demonstrates a standard period, and inside that, a necessary measure of work should be done through adhering to the standard method with the specialist’s “standard execution”. For estimating how much time is required for doing an unmistakable measure of outstanding burden, legitimate SMV set up is required in the articles of clothing generation floor. Standard Time = (Average watched time X Rating %) + Allowance%

Low-Performance Optimization

An organization’s general execution relies upon the commitment of each employee, and an organization is just as solid as its most minimal performing workers. Low entertainers are the individuals who battle to do his/her activity as per the standard strategy or method and who is making issues different administrators in the entire segment. The producers who ordinarily take additional time than setting up, produce lesser than the target and causing bottlenecks, causing surrenders while doing the activity and revamps should have been done, and so on are named as low entertainers. Activity the board can improve the low entertainers through recognizing the causes they are confronting and wiping out those and giving them the correct preparation with the goal that they can comprehend their activity quite well.

Progressive Bundle System

Bundles comprise of an article of garment parts need to finish a particular activity of the piece of clothing segment. In a readymade piece of clothing producing plants, the makers introduce different sorts of sewing frameworks. Activity head picks these frameworks relying upon the volume of production, item classifications and cost-viability of cutting edge machines. Among those “Dynamic Bundle System (PBS)” is, for the most part, introduced sewing framework to date. In this production framework, bundles of cut pieces (heap of 5, 10, 15, 20 or 25 pieces) are moved physically to sustain the line. At that point inside the line, an administrator himself hauls the group from the side table and moves the pack to the following administrator after the culmination of the work. Quality auditors track the bundles on the off chance that they are coming successively.

Reduce and Control the Eight Wastes 

i. Transportation Waste caused by moving things around. Too much transportation tends to increase costs, wastes time, increases the likelihood of product damage and deterioration and can result in poor communication. Limiting transportation waste can be easily addressed by sound judgmental efforts such as simplifying processes, repairing physical layouts, handling products less often, and making distances between workstations as short as possible.

ii. Inventory Work in Process (WIP) Inventory is material between operations due to large lot production or processes with long cycle times. This waste occurs when there is supply more than real operators’ demand, which masks real production. Approximately 60% of wastes occur in the garments industry due to inventory

iii. Motion Any excess movement that doesn’t add value to the product, service or process [9]. The motion includes any unnecessary physical motions or walking by workers which diverts them from actual processing work. iv. Skill Not or under-utilizing peoples’ talents, skills, and knowledge can have a detrimental effect on an organization. Companies can experience great benefits when recognizing the value of skills and breakthrough performances from all levels and can suffer when not effectively engaging in the process.

v. Waiting This occurs whenever work has to stop for some reasons: because the next person in line is overwhelmed because something broke down because operators are waiting for approval of materials, or because they’ve run out of something.

vi. Overproduction Unnecessary production of more quantities than required can be termed as overproduction. In some organizations, workers just blindly keep producing, even when those who receive their output either aren’t ready for it or don’t need it. Line balancing and improved work design can contribute primarily to reduce the waste of overproduction.

How to develop the Garments production Line Efficiency & Productivity

vii. Over-processing When a revise or redone of procedure or product happens for something because it wasn’t correct for the first time or taking unneeded steps to process the parts, inefficiently processing due to the poor tool and product design, causing unnecessary motion and producing defects. In the apparel industry, this waste relates to defects because operators often produce alterations on their operations and so rework needed to be done regularly.

viii. Defects Mistakes that require additional time, resources, and energy to fix. In the manufacturing process, a defect might involve a defective part that the worker has to redo. Production of faulty parts or correction, repair or rework, scrap, replacement production, errors in paperwork, provision of incorrect information about the product, late delivery, and inspection mean extravagant handling, time, and effort.


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