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Lecture 2

Lecture 2. Cutting Department. Outputs…. Cutting Wastages End Loss Width Loss Buffer Loss Remanent Loss Splice Loss. Calculation of losses…. Length of Spread = 480 cm Width of Spread = 173 cm Length of marker = 474 cm Width of marker = 167 cm Spread per day = 7

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Lecture 2

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  1. Lecture 2 Cutting Department

  2. Outputs… • Cutting Wastages • End Loss • Width Loss • Buffer Loss • Remanent Loss • Splice Loss

  3. Calculation of losses… • Length of Spread = 480 cm • Width of Spread = 173 cm • Length of marker = 474 cm • Width of marker = 167 cm • Spread per day = 7 • GSM = 181

  4. Calculation of losses… • # of plies per Spread = 80 • Price of plain fabric = 340 Rs /Kg • Price of printed fabric = 445 Rs /Kg • # of splices per layer = 4 • Marker Efficiency = 85 % • Average Length of Splice = 30 cm • Plain fabric: Printed Fabric = 60 : 40

  5. What is the performance? • End Loss • Width Loss • Remanent Losses • Buffer Loss • Splice Loss

  6. Recommendations for Improvement • Buy a fabric of even better quality • Vender Assessment • Try to Reduce End Loss • Try to Reduce Width Loss • Try to improve Marker Efficiency

  7. Consumption calculations… • First of all deeply analyze the garment • Identify # of different type of fabrics used • Identify total # of parts of a garment • Calculate the area of each part of the garment • Add seam allowances • Add area of all the garment parts • Multiply with the required number of garments • Add your departmental losses

  8. Consumption Calculation

  9. Sewing Department

  10. XYZ Company • Mr. Sajid is Manager of Sewing Department • He receives a sewing plan right after reaching in his office daily.

  11. Inputs… • He demands following things • Specification Sheet from PD / Merchandizing • After wash measurements • Fabric Information • Placements • Trims and Accessories details • Style Bulletin • SMV’s • Before wash measurements • Thread and Consumption details

  12. Inputs… • He demands following things • Cutting from Cutting department / WIP • Cutting quality report from Quality Department • Trims and Accessories from store • Required # of machines from mechanical department

  13. Processes… • Stitching according to the specifications • Measurements within tolerance • Faults less stitching • No Major or minor faults • No faults regarding Trims and Accessories • Meet production targets

  14. Reports… • Hourly Production Report • Daily Production Report • Daily Quality Report • Major Faults Report • Sewing Order Report

  15. Sewing Calculations… • After Wash Measurements • Production Run? • # of machines • SMV? • Yield? • DHU • Efficiency at all levels • Time Wastage

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