Face to Face Layout system in Garments Sewing Line with Advantages and Disadvantages
Sharmin Akther Diba
Industrial & Production Engineer
Rajshahi University of Engineering & Technology (RUET)
Email: dibasrmn@gmail.com
LinkedIn: Sharmin Akther Diba
Introduction
The layout is the first thing to do if you want to start a sewing line. Sewing layout is different for every individual style. A permanent layout setting is a key thing for saving manpower, machine, and transportation handling systems.
Sewing Line Layout
We did a case study on the garments sewing line. Study was two Layout systems of Garments Manufacturing. One is Straight Line layout which is currently running in our facility and another is proposed Layout 'Face to Face Layout'. If you want to know about these two Layout systems of the sewing process, here this article is only for you.
Sewing Line Layout
We did a case study on the garments sewing line. Study was two Layout systems of Garments Manufacturing. One is Straight Line layout which is currently running in our facility and another is proposed Layout 'Face to Face Layout'. If you want to know about these two Layout systems of the sewing process, here this article is only for you.
 |
| Face to Face Layout System |
Objective:
1. To compare running & proposed layout system
2. To Highlight the advantages & disadvantages of the proposed layout system
Straight Line Layout system Vs Face to Face Layout system:
Category
|
Straight Line Layout system
|
Face to Face Layout system
|
Type of layout
|
Straight-line layout-Overhead
material movement
|
Face to face layout- Zigzag
material movement
|
Sitting arrangement
|
Wooden stool without any backrest
|
Rotating chair with backrest
|
No. of machine
|
26-28 machine/line
|
38-40 machine/line
|
Line width
|
Conventional- 6 feet 8 inches
|
Need width extension- 7 feet 2
inces
|
Wire arrangement
|
Conventional electrical connection
as well as lighting
|
Re-arrangement as per line layout
|
Air compressor
|
Conventional air compressor line
|
Re-arrangement as per line layout
|
Bundle keeping basket
|
No bundle keeping basket, material
movement through side table
|
Need bundle keeping basket for
every workstation
|
Machine width extension
|
Not necessary as material movement
through side table
|
Need machine width extension
through wooden pallet as there will be no side table
|
Thread trimming
|
Manually done or there are some
machine with auto trimming facility
|
Need auto trimming facility in
every machine so that use of assistant operator become optimal
|
Bundle size
|
Big bundle size, typically 50 to
60 PCs
|
Bundle size need to resize, 10 to
20 PCs
|
Kanban/andon boards
|
No kanban/ andon boards in line
& front
|
Need kanban/ andon boards in line
& front
|
Advantages of Straight Line layout system Vs Face to Face Layout system:
Sl.
|
Category
|
Straight Line Layout system
|
Face to Face Layout system
|
1
|
Tracking & monitoring
|
Difficult to tracking & monitoring production & quality
|
Easy to tracking & monitoring production & quality
|
2
|
Utilization of machine
|
26-28 machine/line in conventional
|
more 10-12 machine can be used inline
|
3
|
Transportation time
|
Material transportation time is more
|
Material transportation time is less
|
4
|
Product type
|
Any kind of item in the production line
|
Basic/ small items in a production line
|
5
|
Layout doubling
|
Single item run in production line
|
Two basic items can be run in production line
|
Disadvantages of Straight Line layout system Vs Face to Face Layout system:
Sl.
|
Category
|
Straight Line Layout system
|
Face to face Layout system
|
1
|
Garments handling
|
Any length or size item can be handled
|
Only basic/ small items can be handled
|
2
|
Product variation
|
Any kind of product can be run online
|
Limited product type as long/big garments handling the issue
|
Expected result:
1. Transportation
time reduction
2.
Ergonomically designed work-station
3. Proper
tracking of production & quality
4. Visual
management in the production floor