work Study -Part 2 (CLASSIFICATION OF BEHAVIOR)

Main operation: The operation rate of the machines should be enhanced by standardizing the work or rationalizing the of control method. Rationalized types of machine should be introduced. Ancillary facilities should be used effectively. Attachments should be adopted.

Sewing, operating an iron, Pressing, Actuation of the pulley, thread take-up and needle bar, processing the material.

Associated operation: Material handing devices should be adopted. Work benches and tacks should be improved. Training in machine operations should be developed. The material setting method should be improved.

Picking up, Placing, Changing the holding position, and setting (the materials), Cutting the thread, Fitting

Condition arrangement: The lot size should be increased. Workers should be assigned to shared work (to simplify the work allotted to each worker). Spare sewing machines and irons should be made available. The equipments should be installed in their predetermined locations.

Checking the instructions, Replacing the attachment, Adjusting the height of the chair, Spraying silicon, Adjusting the tension of the bobbin thread, Checking the temperature of the press and iron.

Product arrangement: The processes should be well-balanced. The processing order should be standardized. The shelves for product arrangement and the materials should be stored in predetermined positions. Racks and assembly tables should be used.

Preparing the materials, Changing the setting positions of the materials, Binding and undoing the materials, Checking the quantity of materials.

Trouble: Prevention and maintenance of the correct state. The thread to be used should be investigated. Needle thread should be used. How to handle the sewing machine. How to depress the foot pedal.

Re-threading the machine in case of thread breakage, Replacing a broken needle, Changing a needle, Malfunctions of the sewing machine, vacuum board or press

Preliminary arrangement: Work training. How to educate the workers. Written instructions. Report system.

Instruction, Report, Education, Consultation

Fabric Inspection Procedure (Four Point System)

FABRIC INSPECTION PROCEDURE:

This procedure shows the steps necessary to ensure an effective fabric inspection quality control program:

1. Determine the fabric quantity to be inspected.

2. Select the fabric rolls for inspection.

3. Place the fabric roll / bale on inspection frame / table.

4.Cut off a 6-inch piece across the width of the fabric from the beginning of the roll. 

Mark this piece so that the inspector will know the right and left side of the fabric. 

Use the strip to check the shading side-to-side and end-to-end by checking it at least 

against the middle of the roll and once at the end of the roll.

5.Inspect for visual defects at a speed slow enough to find the defects.

6. Check that the roll contains the meters as stated by the Fabric Supplier.

Check for bowing & skewing in the fabric

ROLL-TO-ROLL SHADE CHECKING SYSTEM:

Textile links and Controls suggests to use a format for the checking of all fabric shade variations from roll to roll. In this format water falls of different shades’ categories of different rolls is maintained and compared to each other to check the extent of the shading variation.

If any shade requires special attention / treatment in the cutting, it is mentioned in the remarks column.

If any fabric is out of tolerance with respect to the Master Sample or the shade variation extent among the rolls is out of tolerance, then the fabric is reject. The rejected fabric is sent back to Fabric Supplier for reprocessing / replacement.

TOOLS FOR FABRIC CHECKING:

The person who is responsible for fabric inspection must have the following facilities / equipment in good working condition.

1. Inspection frame with counter.

2. D - 65 light source (sunlight) / TL - 84 light source at the inspection frame as per the requirement of the customer.

3. Measuring tape & pair of scissors.

4. Stickers or masking tape to identify the faults.

5. Pick glass.

6. Digital Camera for taking reference snaps.

7. Master fabric sample or customer’s reference sample. 

Four Point System:

The four-point system derives its name from the basic grading rule that a maximum of four penalty points can be assessed for any single defect and that no linear meter can be assigned more than four points regardless of the number of defects within that piece.

PENALTY POINT EVALUATION:

Defects in both warp / fill directions will be assigned points under the following criteria.

CARTON MEASUREMENT USE FOR CONTAINER

Basically Carton Measurement uses for different Types of Container.Two Types of Container are used for international goods transport.
One of 20 Ft Container and 40 Ft Container.

20 Ft Container = 30 CBM (Cubic Meter)
40 Ft Container = 60 CBM (Cubic Meter)

In Carton,
Length = 40 Cm
Width = 20 Cm
High = 15 Cm

   Length X Width X Height
= (40 X 20 X 15 ) Cm
= .40 X .20 X .15
= .012
=60/.012 (If Container is 40 ft)
=5000 Cartoon

Carelevel Instruction for Apparel Items

This Chart illustrates care symbol accepted by federal trade commission as part of a conditional exemption to the FTC Care labeling Rule (16CFR 423) This chart is referenced from ASTM D5489-98c.This Symbol are used for Commercial and Home laundering Dry cleaning.

Basic Denim Long Pant Consumption

We have the bellow measurement of a "Basic Denim long pant" :-

Inseam = 34 inch,
½ Thai= 13 inch,
Back rise (Under West Band) =15 Inch
Waist band width =1.5 inch,
Back pocket length = 7 inch,
Back pocket Width = 6.5 inch
Belt Loop length =1.5 inch,
Belt Loop Width = 1/2 inch
Pocket Bag Length = 7.5 inch
Pocket Bag Width = 6.5 inch

The Formula is : ( Length X Width ) X No of panel / ( Fabric Width X 36 inch ) + Wastage Percentage

= Result X 12 Pcs

Calculation: - In Here

Total Bottom Length = Inseam + Back rise + Wbw + Sewing allowance.( Wbw =West band width )

Total Bottom Width = 1/2 Thigh +2“ Sewing allowance

So, Length = 34+15 + 1.5 *2 +3 = 55 Inch.
Width = 13 +2 =15 Inch

Say the actual Fabric Width is 58 inch, but when sewing a garments as we can’t use the edge of a fabric , so at the time of calculation we must deduct 1 Inch from the fabric width . I.e. fabric width will be 57 Inch.


Now the Applicable Formula :-

( Length X Thigh ) * 4 part /( Fabric Width X 36 inch)

= Result + 5 % Wastage

= Result for 1 Pc X12 pcs

= Yds / Doz

Based on above information we found

Main Fabric Consumption :- (55 Inch X 15 Inch) X 4 Pcs /57 inch X 36 Inch + Wastage 5% X 12 Pcs

=( 3300 square inch / 2052 square inch )+ 5% Wastage X 12 Pcs

= {1.61 Yds +0.08(Wastage)} X 12 Pcs

= 1.69 Yds X12 Pcs

= 20.28 Yds /Doz.


Back Pocket Consumption = (7”X 6.5 )=44.5 X 2 pc / 57 X 36 =91 /2052 =.044 +.0022=.047 X12 Pcs

= 0.56 Yds / Dz

Belt loop Consumption = (1.5”X .5 ) = .75 X 6 pc / 57 X 36 =4.5 /2052 =.0022 +.0001=.0023 X12 Pcs
= 0.028 Yds / Dz

Total Fabric =20.28 yds +0.56 Yds+0..28 Yds = 20.84 Yds / Dz

For Pocketing Fabric :- Length =7 .5 inch X 2 Ply +1 inch (SA )=( 15+1) inch = 16 inch

Width = 6.5 inch X 2 Ply + 1 inch (SA )= 14 inch

= ( 16 inch X 14 inch )2 pcs /(43 inch X 36 inch)
= 448/1548

=.29+5% wastage=.28+.0145=0.30X 12 Pcs =3.65 Yds Per


So we can say, based on above measurement we need 20.84 Yds main fabric & 3.65 Yds pocketing fabric to make 12 Pcs Basic long pant. this way we can calculate fabric consumption for any quantity.