Sewing layout: Sewing layout refers to the organized
arrangement of machines, workers, and workstations in a sewing section or
garment production floor to ensure smooth workflow, maximum productivity, and
minimal handling or movement.
How to improve production efficiency?
Improving production efficiency in basic T-shirt
manufacturing requires focusing on both technical and management aspects of
production.
1.
Method Study & SMV Optimization
Break down each operation (e.g., sleeve
join, side seam, hem, neck rib join, etc.).
Use motion study (time and motion) to
eliminate unnecessary movements.
Reduce SMV (Standard Minute Value) by
simplifying or combining operations where possible.
2.
Line Balancing
Assign operators according to their skill
level and speed.
Distribute work so all operators are busy
without bottlenecks or idle time.
Use balance chart or tools like Excel to
plan smooth operation flow.
3.
Operator Skill Development
Train operators to improve speed and
quality.
Introduce multi-skill training to make
workers flexible.
Use incentive systems for motivation.
4.
Quality Control at Source
Implement inline quality checking instead
of final-only checks.
Reduce rework and
rejection—first-time-right production saves time.
5.
Improve Material Handling
Use trolleys or conveyor systems instead of
carrying bundles by hand.
Apply bundle tickets or barcodes for
tracking.
6.
Use of Proper Machines & Attachments
Use folder attachments for neck joining,
sleeve hemming, etc.
Ensure machines are maintained well—no
downtime.
7.
Layout Optimization
Apply straight-line or U-shaped layout for
better workflow.
Minimize movement of garments between
processes.
8.
Production Monitoring
Use hourly production tracking boards.
Monitor efficiency, output, and WIP in live time.
9.
Pre-Production Planning
Ensure all trims, fabrics, and patterns are
ready before starting the line.
Conduct pilot production to find and fix
issues early.
10. Lean
Manufacturing Tools
Apply 5S (Sort, Set, Shine, Standardize,
Sustain).
Introduce Kaizen (continuous improvement
ideas from workers).
Use KANBAN or pull systems for material flow.
Basic t-shirt operation breakdown/bulletin/layout.
|
Operation Breakdown |
Machine |
|
BACK & FRONT PART
MATCH |
Helper |
|
SHOULDER JOIN |
Overlock Machine |
|
NECK MAKE |
Plain Machine |
|
NECK SERVICING |
Overlock Machine |
|
NECK JOIN |
Overlock Machine |
|
BACK NECK PIPING & MARK |
F – F/C Machine |
|
BACK NECK PIPING CLOSE
WITH LABEL |
Plain Machine |
|
FRONT NECK T/S |
C - F/L Machine |
|
CARE LABEL MAKE |
Plain Machine |
|
SLEEVE PAIR & MATCH |
Helper |
|
SLEEVE JOIN |
Overlock Machine |
|
SIDE SEAM |
Overlock Machine |
|
BODY REVERSE |
Helper |
|
SLEEVE HEM |
C - F/L Machine |
|
BODY HEM |
C - F/L Machine |
|
TRIMMING & FINAL
CHECK |
Helper |
Regards,
Azizul Haque Anik
BSc in Textile Engineering, Rangpur Textile Engineering
college
Officer- IEP Department, GMS Composite Knitting Ind. Ltd.