Stitching is the core process in garment manufacturing in the apparel and fashion industry supply chain.
For example, a production line involves different types of sewing machines, non-sewing equipment, and workstations for manual processes. Each workstation is designed for an operation.
In the apparel manufacturing industry, most garment manufacturers use the assembly line for making clothes and garments. In the assembly line, a number of sewing machines (including different types of sewing machines and non-sewing equipment) are placed in a line according to the process sequence requirement. Garment bundles are loaded at one end of the line and moved from one workstation to another, and finally stitched garments come out from the line.
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| An Assembly Sewing Line |
Define Line Layout
When we talk about preparing a line layout it means designing the presentation of workstations in an assembly and showing the flow of work from start to end operation. It can be a simple line diagram. See the following image. The rectangle boxes indicate the sewing workstation. The numbers marked inside the boxes indicate the operations sequence in the Operation Bulletin (OB) and arrows show the flow of work. The line layout is prepared after the operation bulletin is made.
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| A sample line layout line diagram |
There are different types of sewing line layouts. Whatever the line layout one factory uses industrial engineers need to prepare a line layout for the upcoming orders.
For example, a production line involves different types of sewing machines, non-sewing equipment, and workstations for manual processes. Each workstation is designed for an operation.
When you prepare the line layout, you will see the following cases and you will define a workflow on the line layout.
- You may need to assign more than one workstation for the same operation,
- You may need to use the same machine (workstation) for more than one operations
- You may need to load bundles or garment components in multiple workstations
Why do you prepare a line layout?
Following are some of the primary benefits and applications of preparing line layouts.
- The line layout helps line supervisors to set up the line for a new order in the least time.
- From the layout, you will get the exact requirements of machines and equipment. The production team can be better prepared
- Style changeover time can be reduced by preparing a detailed line layout and doing line set-up based on the line layout
- For a new plant set-up, designing the line layout is an essential part. Looking at line layout, overhead wiring, air connection, installation of ironing tables, QC tables, and fixtures installed.
In case a factory produces the same product all the time, it still needs to change the line layout depending on the product design. In such cases, the factory may need a minimum change of sewing machines and workstations.
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