Cutting Fabric for Garments
A
Standard Garments can achieve greater efficiency by considering their cutting
room. Standard Garment should fully work
in new layout. And this layout fully compliance maintain. It also give to
target Lay spreading, Numbering & Scissoring for better production. It
should have Input Reporting Format like follow-up per hours input and input problem we are try to solved
& go door to door for finding actual problem. Cutting managers have some duties to flow up this process. Read more about Garment Cutting Software for Production Management ...
Purpose:
To ensure that only an acceptable quality of fabric is used
for producing garments & proper quantity of shipment is received from the
supplier.
Cutting View
The incoming fabric is received by assistant store manager.
This fabrics are stored at fabric Go down by tagging buyer, style name &
fabric type. Cutting quality in charge cut the blanket from each roll. The
blankets are sewing by O/L & quality inspector will take the measurement.
Then send to the buyer recommend washing process by wash merchandiser.
- The Standard Garments Cutting Fabric are work in together.
- There 16 spreading table for 25 lines.
- Total Table length :861 feet
- Average Table Width :5.58 feet.
- Total Square feet :4808.69 feet .
- Previous table length :1068 feet.
- Reduce table length :1068-861 = 207 feet save.
- Previous space = 17348 square feet .
- Save space=17348-16190=1158 square feet.
Manpower
After completing the wash process it has been sent to
cutting quality inspector by wash merchandiser.
- Previous manpower : 199 Man
- Present Manpower : 176 Man
- Reduce manpower : 199-176 = 23 Man .
Saving Costing :
Average Salary = 6100 taka BD
Saving man = 23 X 6100 = 140300 taka (One Month )
One Year = 140300 X 12 = 1683600 taka BD
Target Setup
Then these blankets are divided into different types of
shade. Then tag the fabric in go down as per shade. (Such as A, B, C, and D). Shrinkage test also done at this stage if the shrinkage is
more than (+/- 5%) This fabric is considered as rejected. Before wash measurement-After wash measurement *100. Before wash measurement. The quality inspector will take 10% of total received yards
then this fabric checked by fabric inspection machine. They check length, width
& defects.
- Standard Garments setup target against SMV.
- Which had been observation last 6 month .
- Finally we got SMV.
- Making Cutting Fabric bulletin (operation breakdown)
- Target Setup :
- Making capacity graph on qc by Time study.
- Finding individual numbering capacity.
- VSM (Value Stream Mapping) continue.
- Making worker determination salary. (continue )
Efficiency
If the length is different from invoice sheet it is informed
to concern merchandiser, he is responsible to fill up the gap. After confirming the length- the length, width is recorded
by Assistant Store Manager. At fabric inspection machine defect also checked by four
points system and record it as fabric inspection report.
Formula :
- Output Min : Working hrs X 60(min)X Manpower.
- Input Min : Total Production X SMV.
- Last three month average efficiency :
- Month of July Efficiency : 58 %
- Month of August Efficiency : 57 %
- Month Of September Efficiency : 57%
Cutting Demand
The four points system is named from a basic grading rule,
regardless of length/size or number of defects, no more then 4 penalty points
may be assigned on any linear meter/yard.
Defect should be marked with a colored sticker. To
show defects position it should be marked with the same color of sticker.
Defects in both warp/weft directions will be assigned points using the
following criteria - Fabric & Accessories in-house in just time.
- Proper planning set up.
- Production Sample & Marker in-house in just time.
- Fabric fault are approved before bulk cutting .it can be clear during fabric inspection time.
Cutting Sheet
[This sheet is applicable to only cotton, T/C and similar fabric in usual room temperature, illumination and humidity and the applicability may change with the change(s) of working condition(s) and workers’ performance]
PROCESS DESCRIPTION
|
OPTIMUM CONDITIONS
|
HOURLY STD. PDN.
|
STD. PDN. IN MINUTES
|
SINGLE SCISSORING
(SMALL-SHORT SLEEVE, YOKE)
|
1 person (A=1), 1 sharp scissor
|
360 PCS
|
6 PCS IN 1 MIN
|
SINGLE SCISSORING
(LARGE-FRONT, BACK, LONG SLEEVE)
|
1 person (A=1), 1 sharp scissor
|
324 PCS
|
11 PCS IN 2 MIN
|
SINGLE SCISSORING
(TESCO)
|
1 person (A=1), 1 sharp scissor
|
600 PCs
|
10 PCS IN 1 MIN.
|
PAIR SCISSORING
(SMALL-SHORT SLEEVE, YOKE)
|
1 person (A=1), 1 sharp scissor
|
539 PAIR
|
18 PAIR IN 2 MIN.
|
PAIR SCISSORING
(LARGE-FRONT, BACK, LONG SLEEVE)
|
1 person (A=1), 1 sharp scissor
|
404 PAIR
|
20 PAIR IN 3 MIN.
|
PAIR SCISSORING
(TESCO)
|
1 person (A=1), 1 sharp scissor
|
1100 PAIR
|
18 PAIR IN 1 MIN.
|
RE-LAY
(FRONT, BACK, LONG SLEEVE)
|
2 persons (A=1,C=1)
|
360 PCS
|
6 PCS IN 1 MIN.
|
RE-LAY (YOKE, SHORT SLEEVE)
|
1 persons (C=1)
|
600 PCS
|
10 PCS IN 1MIN
|
RE-CUTTING (AFTER RE-LAY)
|
1person(A=1), 1M/C
|
18 LOT
|
1 LOT IN 3MIN.
|
BAND KNIFE CUTTING (AFTER BLOCK CUTTING)
|
1person (A=1), 1 M/C
|
30 LOT
|
1 LOTS IN 2 MIN.
|
NUMBERING (LARGE COMPONENT: -FRONT, BACK, SLV, YOKE)
|
1person (B=1), 1 Pen/Pencil
|
1400 PCS
|
23 PCS IN 1 MIN.
|
BUNDLING
|
1 person (C=1), Pen, Bundle Card, Extra Fabric
|
80 BUNDLES
|
4 BUNDLES IN 3 MIN.
|
NUMBERING & BUNDLING (LARGE COMPONENTS -FRONT, BACK,
SLV, YOKE)
|
1 person (B=1), 1 pen/pencil
|
1200 PCS
|
20 PCS IN 1 MIN.
|
NUMBERING & BUNDLING (SAMLL COMPONENTS -CUFF, CLR,
PLKT, PKT, BAND)
|
1 person (B=1), 1 pen/pencil
|
1620 PCS
|
27 PCS IN 1 MIN.
|
RECUTTING FOR PANEL CHECK REPLACEMENT
|
1 person (A=1), 1 sharp scissor
|
30 PCS
|
1 PCS IN 2 MIN.
|
A-Skilled, B- Semi Skilled, C-Unskilled
N.B.: This sheet is generated and controlled from the IE department, Auto Group. The above results were emerged from scientific experiments & observations.
Next action plan on Cutting Fabric
- Reduce time on lay preparation & marker fitting time on fabric lay.
- Time & Action plan on cutting.
- Understand the fabric quality before cutting
- Discuss the improvement required on the failed rolls with the fabric supplier
- Guide for the best fabric sourcing decision
- Provide a profile of each quality
- Provide a profile of each fabric supplier’s performance season by season.
- Daily cutting plan with auto bundle card system.
- To continue Cutting Fabric NPT.
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