Sewing Thread Consumption of Garments

Approx. sewing thread consumption of different items
No.	Product name	Consumption
1	Basic t- shirt	125 Meter
2	Basic polo shirt	175 Meter
3	Tank top	50 Meter
4	Fleece/Sherpa jacket	250 Meter
5	Kids/girls dresses	300-450 Meter
6	basic long sleeve woven shirt	150 Meter
7	Basic short sleeve woven shirt	125 Meter
8	basic long trouser/pant	350meter
Machine and Sewing Wise Consumption/Inch
1	Plain m/c	1 needle	2.5 inch
2	Plain m/c	2 needle	5 inch
3	Chain Stitch	1 needle	5 inch
4	Over lock	3 thread	13.25 inch
5	Over lock	4thread	16.75inch
6	Over lock	5 thread	18.75inch
7	Flat lock	3 thread	16.75inch
8	Flat lock	5thread	22.25inch
9	Bar tack stitching	Per operation	Generally 7 inch

A Garments having 104 inches 4 Threads Over lock stitches, 52 inches 5 Thread Flat lock stitches, 20 inches 1 Needle Chain stitches, 15 inches Single Needle Plain Machine stitches, GSM is normal, find out its thread consumption in meters? 

Answer: {(104 x 16.75) + (52 x 22.25) + (20 x 5) + (15 x 2.5) + 10%} / 39.37 = 77.76 Meters. (39.37 inches = 1 Meter) 

*** Suppose, we want to buy thread cones with 2000 meters thread, now figure out how many cones do we need to stitch 30000 pcs of garments, per garment’s thread consumption 77.76 meters? 

Answer: 77.76 x 30000 / 2000 = 1167 cones. 

How to calculate Consumption in Garments?

Knit fabrics are usually measured in kilogram whereas it is related to GSM as well. Knit fashion is now popular in the world market. Knit merchandising is not so easy thing whatever consumption is one of the key factors for knit merchandising. T-shirts, pull over, polo-shirt (long sleeve or short sleeve) are treated as knit top garments as well as trouser and pant are treated as knit bottom garments.

Consumption formula for any TOP knit Garments

 (Measurement in CM)

{(B.L + S.L. + Allowance) X (1/2 Chest + Sewing Allowance) X 2 X GSM X 12 ÷ (10000 X 1000)} +Wastage%   kg/dz   

Here,

1.   Body length of the garments in cm. Say it is - 73 cm

2. Sleeve length of the garments in cm. Say it is - 19.5 cm

3. Approximate sewing allowance at body hem, shoulder joint, sleeve hem & armhole joint (in cm). Say it is - 10 cm 

4. Chest width (1/2) in cm. Say it is - 52 cm

5. Approximate sewing allowance at both side seams (in cm). Say it is - 4 cm

6. Fabric GSM (finish). Say it is - 160 gsm

7. Approximate fabric wastage in various stages. Say it is - 10%
8. 10000 means cm is converted into meter

        9. 1000  means gram is converted into kg

Rules: 

= {(B/length + S/length + Sewing Allowance) X (1/2 Chest + Sewing Allowance)}X 2 X GSM X 12 / 10000000 + Wastage
= {(73 + 19.5 + 10) X (52 + 4)} X 2 X 160 X 12 / 10000000 + 10%
= (102.5 X 56) X 2 X 160 X 12 / 10000000 + 10%
= 5740 X 2 X 160 X 12 /10000000 +10%
= 22041600 / 10000000 + 10%
= 2.20416 + 10 %
= 2.424576
= 2.43 kg per dozen. (Consumption)

(Measurement in INCH)

(B.L + S.L. + Allowance) X (1/2 Chest + Allowance) X 2 X GSM X 12 ÷ (1550X 1000) +Wastage%    kg/dz   

Here, 

B.L - Body Length

S.L - Sleeve Length

Allowance - Allowance would have considered for both B.L and S.L

1550 means inch is converted into meter (1 inch = 39.37" where inch square will be 39.37"X39.37")

1000 means gram is converted into kg

Different Types of Trimmings and Accessories in Garments

Introduction:

Garments manufacturing is the only goal of others textile manufacturing processes. To make garments and shipping it up-to the buyer, trimmings and accessories has a great importance in garments manufacturing. There are different types of trimmings and accessories which are used in garments manufacturing are mentioned in the following.

Types of Trimmings and Accessories:

Trimmings:

The materials which are attached with the body of garments by sewing are termed as trimmings. One point should be noted in case of trimmings, all the trimmings are used as functional purposes.

                                                              Different Types of Trimmings

Another one non-technical explanation is that, trimmings are the ultimate materials that are attached with the garments while using by end user.

Different types of trimmings items are mentioned in the following:

1.    Sewing Thread,

2.    Button,

3.    Rivet,

4.    Stopper,

5.    Interlining,

6.    Lining,

7.    Metal Badge,

8.    Elastic,

9.    Zipper,

10.  Shoulder Pad,

11.  All types of Label such as main label, care label, size label etc.

12.  Hook and Loop,

13.  Twill Tape,

14.  Velcro Tape

15.  Lace.

Accessories:

The materials which are not attached with the body of garments by sewing, only used for garments finishing and packing (decorative purposes) are termed as accessories. The main difference between trimmings and accessories is, trimmings are used as functional purposes and accessories are used as decorative purposes.

   

                                                        Garment accessories

Another one non-technical explanation about accessories is that, Accessories are the ultimate materials that are not attached with the garments while using by end user.

Different types of accessories items are mentioned in the below:

1.    Collar stand,

2.    Carton,

3.    Carton sticker,

4.    Safety sticker,

5.    Hanger,

6.    Draw cord/ String,

7.    Back board,

8.    Neck board,

9.    Collar stay,

10.  Butterfly,

11.  Patch,

12.  Gum Tape,

13.  Price ticket,

14.  Poly bag,

15.  Safety Pin,

16.  Tag pin,

17.  Brass Pin,

18.  Buckle,

19.  P.P belt,

20.  Tissue paper,

21.  Size strip,

22.  Pocket flasher,

23.  Hand tag,

24.  Photo in lay,

25.  Both Side Tape,

26.  Plastic Clip.

Production Planning and Control (PPC)

Introduction

For efficient, effective and economical operation in a manufacturing unit of an organization, it is essential to integrate the production planning and control system. Production planning and subsequent production control follow adaption of product design and finalization of a production process.

Production planning and control address a fundamental problem of low productivity, inventory management and resource utilization.

Production planning is required for scheduling, dispatch, inspection, quality management, inventory management, supply management and equipment management. Production control ensures that production team can achieve required production target, optimum utilization of resources, quality management and cost savings.

Planning and control are an essential ingredient for success of an operation unit. The benefits of production planning and control are as follows:

• It ensures that optimum utilization of production capacity is achieved, by proper scheduling of the machine items which reduces the idle time as well as over use.
• It ensures that inventory level are maintained at optimum levels at all time, i.e. there is no over-stocking or under-stocking.
• It also ensures that production time is kept at optimum level and thereby increasing the turnover time.
• Since it overlooks all aspects of production, quality of final product is always maintained.

Production Planning

Production planning is one part of production planning and control dealing with basic concepts of what to produce, when to produce, how much to produce, etc. It involves taking a long-term view at overall production planning. Therefore, objectives of production planning are as follows:

• To ensure right quantity and quality of raw material, equipment, etc. are available during times of production.
• To ensure capacity utilization is in tune with forecast demand at all the time.

A well thought production planning ensures that overall production process is streamlined providing following benefits:

• Organization can deliver a product in a timely and regular manner.
• Supplier are informed will in advance for the requirement of raw materials.
• It reduces investment in inventory.
• It reduces overall production cost by driving in efficiency.

Production planning takes care of two basic strategies’ product planning and process planning. Production planning is done at three different time dependent levels i.e. long-range planning dealing with facility planning, capital investment, location planning, etc.; medium-range planning deals with demand forecast and capacity planning and lastly short term planning dealing with day to day operations.

Production Control

Production control looks to utilize different type of control techniques to achieve optimum performance out of the production system as to achieve overall production planning targets. Therefore, objectives of production control are as follows:

• Regulate inventory management
• Organize the production schedules
• Optimum utilization of resources and production process

The advantages of robust production control are as follows:

• Ensure a smooth flow of all production processes
• Ensure production cost savings thereby improving the bottom line
• Control wastage of resources
• It maintains standard of quality through the production life cycle.

Production control cannot be same across all the organization. Production control is dependent upon the following factors:

• Nature of production (job oriented, service oriented, etc.)
• Nature of operation
• Size of operation

Production planning and control are essential for customer delight and overall success of an organization.