How to Setup Machine Layout for Basic Woven Shirt in Garments Industry

The shirt has become one of the most common and popular items of menswear, though women also do not lag behind in making use of them. There are varieties of shirt design. Some are formal and basic white; others are casual types and may incorporate unique design features. Shirts have become the most popular outer wear in the hot & humid countries. Cold countries find them as common apparel worn under a coat or jacket. It should be noted here that dress shirts are shirts that enable the use of a necktie. Here, I am presenting how to set up a Machine Layout for a Basic Woven Shirt in the Garments Industry.

Different Parts of a Basic Shirt:

Basic shirts comprise the following major parts:

1. Collar (One piece collar, Two piece bounded collar, Multi piece collar etc.),
2. Cuffs (Squared, rounded, pointed, notched, etc.
3. Two full sleeves,
4. Left front with one pocket and buttonhole stand (Top center of front placket),
5. Right front incorporating button stand,
6. Yoke (One piece single yoke, two piece double yoke, etc.
7. Back part,
8. Armhole,
9. Bottom hem,
10. Sleeve placket,
11. Label.

Woven Shirt Sewing Production Line Machine Layout in the Apparel Industry:

The basic woven shirt is very common in the garments industry. Machine layout plan is always a key factor for higher production. If the total plan is executed perfectly, then it will be easy for the production team to meet the shipment date without any hassle. As its importance, this article has presented a well-tested Setup Machine Layout for Basic Woven shirts, formal shirts, casual shirts, or basic shirts.

Setup Machine Layout for Basic Woven Shirt in Garments Industry:

We will make calculations for the body and collar-cuffs-sleeves separately @150pc per hour. Body process operations are shown here. Processes are allocated to operators so as to make a layout for body processes. All the major parts are prepared separately & later assembled together to form a shirt. The process flow diagram of apparel breakdown and their assembly is shown in below:

Machine Layout 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 Sewing 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.