Process Sequence of Garment (Sweater) Operation Breakdown

Process Sequence of Garment (Sweater) Operation Breakdown

Muhammad Rahat
Dept. of Knitwear Manufacturing Technology
BGMEA University of Fashion & Technology (BUFT)

Sweater Operation Breakdown
Breakdown is a listing of the content of a job by elements. A garment consists of some parts and some group of operations. Breakdown means to writing down all parts and all process/operation after one another lying with the complete garment according to process sequence.

1st Step: - Needle Selection from both needle bed.

2nd Step: - Needle setting for rib as per buyer’s requirement

Needle setting by needle selection device

3rd Step: - Prepare rib height by course (c/s) say 10 c/s (Based on WPI, CPI)

4th Step: - Loop transfer from back needle bed to front needle bed

Needle loop transfer from back to front needle bed by transfer comb.

5th Step: - After transferring the loops knot up to armhole point by number of course.

6th Step: - Prepare armhole point by decreasing or increasing – decreasing both demands on styling.

7th Step: - Side by side prepare neck drop and finish up to neck line/ shoulder line.

8th Step: -

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  2. Flow Chart of Proto Sample Development in Apparel Industry

Tragic Fire Incidence in Garment Industry and the Moments for Live Telecast

Tragic fire incidence & the moments for live telecast

Mohammad Nurul Alam
Senior Merchandiser | Asmara BD Pvt. Ltd. | Dhaka | Bangladesh
Cell: +8801930540035,
E-mail: /

The person was rescued from gravels & stones. He was injured seriously & in a life & death situation. Then came another person holding a microphone & camera. He came near & asked - how you feel? Yes, I am talking about big industrial incidence that happen in Bangladesh. Rana plaza tragedy still haunting us. But it was a scenario that mentioned above when a journalist ask this question to seriously injured person. No matter what he asked but the matter is live telecast. So his rational feeling never hold his back to prevent asking stupid question.
Fire in Tongi
Actually why this old matters came again? The reason is recent fire incident that happen at the Tongi in a garment industry. This is a very tragic fire incidence when everyone is preparing for 2nd Eid holiday. I was surprisingly shocked to imagine what the future impact waiting for us in the apparel industry. So very scared for childish activities that our media is doing in name of live telecast.

I am not agree to hide any ting when a garment owner responsible for death of working people. The person who never think of life risk & safety he must be punished by the laws. So that other apparel manufacturers must think about safety & don't push the life in risk in name of profit. If he fails to offer proper businesses procedures then he should not come in the garment businesses. Because we don't want to loss life even if he or she is very ordinary worker. This should not be allowed to throw whole garment industry in challenge & big risk for a few profit maker.

My topic was live telecast for any serious incidence that should not be spread panic among the common people. Even some time this may bring worse situation. The Gulshan tragedy is the best examples when terrorists are watching the live telecast & updating themselves then the situation gone towards worse. Because terrorists want the news should be spread throughout of the world & our media is doing the same unconsciously what they are trying to do. Very funny!!

Now come to live telecast of Tongi incidence. I was watching the TV news then came to know about the tragic accident & loss of casualties. But the reporter is seeming talking unnecessary. He is talking to person who is crossing him. The reporter stop him & asked - do you know what happened? How fire caught & how many people died? The passerby as he himself watching the fire work he give answer what is rumored. Many people died! Many injured! This a big fire. OK then the report tried to catch a fire worker who is trying to extinguish fire. Hi man, can you tell us what happen? The fire man was so busy that he could not show his face in front of camera. The reporter continuing his nonstop report. What supposed to be, what may happen, what is the loss like this many update. Surprisingly everything is coming from his own explanation & imagination. No authorized person is saying what is the loss & how the fire happen & why.

This is actually our media trends. Everyone is trying to give latest update. So talk more & make the situation worse even if it is bad for overall business. Actually every single tragic incidence keeping us scared for our apparel business. Gulshan tragedy, the wound is still not cured where apparel personnel lost life. The new fire incidence again a big shock in the industry. We don't know what is waiting next but should have to think for overall business as well as to punish responsible for tragic incidence.

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  1. The Way of Smart Merchandising
  2. Career in Merchandising: Factory vs Buying House
  3. Copy-Paste Worksheet, A Big Reason for Big Mistake in Merchandising

Copy-Paste Worksheet, A Big Reason for Big Mistake in Merchandising

Copy-paste work sheet, a big reason for big mistake
Mohammad Nurul Alam
Senior Merchandiser | Asmara BD Pvt. Ltd. | Dhaka | Bangladesh
Cell: +8801930540035,
E-mail: /

Generally when merchandiser goes for any booking he takes old worksheet by copy-paste for new work order, suppose accessories or fabric booking format. This is easy to prepare the booking by changing some figure on the sheet. But sometime this can be big disaster for the order. If I am not wrong very few merchandiser can be exception who did not do mistake because of copy paste worksheet reason. In my early career I had also bitter experience that happen due to copy-paste problem.
Worksheet preparation by merchandiser (Symbolic picture)
I can remember it was a booking for single poly. As usual I have taken an old worksheet to go for new work order. Yes, I completed the booking & waiting for poly when it will be in-housed. Finally when time arrives for packing then I realized my mistake. I had changed everything on the old worksheet but forgot to change poly Quantity. The order require twelve thousands poly bag but as old worksheet mentioned three thousand then poly in-housed only three thousand. That means nine thousands poly bag still require to pack for whole of the order. It was very bad situation for me. I was scared & nervous because if the goods not shipped in the next day, goods will air. The worse things happen that the next day was Friday & we were on the Thursday evening. So poly supplier was closed for Friday. However it was very tough to manage everything & finally goods went by sea. The mistake was very simple- quantity was not changed on the worksheet but the suffering was huge just not for me but for everyone those are related with that order. So everyone should have to be careful when using old work sheet for any new booking.

What should have to do when working on old worker sheet?

1. Take a fresh worksheet :
Never take old work sheet rather take fresh work sheet where nothing is mentioned as example no style name, order no, quantity. The worksheet will be just a copy for format only.

2. High light the area where need to change.
If it is excel sheet then put particular color in cell that you can easily understand the cell need to change or put something. Suppose order no, style name, fabrication, required quantity so that the possibility to forget the figure will be less.

3. Cross check for the sheet :
Cress checks means just to see some particular figure. Suppose – correct quality. In my above mistake the problem was in the quantity but not in quality or sizes so additional quantity was needed only. On the other hand if quality is not correct then everything will be disaster. One of my colleague forgot to change quality so put single jersey instead of 1x1 rib fabric then happen the worse thing in his career.

4. Ask co-worker just to have a look
When work-order is ready then take help from co-worker & ask him/her just to have a look on the sheet so that he/she can find something what is overlooked.

5. Don’t be hurry
Need to take extra time before releasing the work sheet so that anything error can be identified. It was said when bullet was thrown from the pistol then nothing left to do so before releasing the bullet should have to confirm the target point.

6. Checking over & over

I know my work order is perfect & so sleeping quietly putting oil in the nose. So relax!! Then came the bad day & left some lesson. So before the final hour comes need to check again & again if anything still requires changing.

7. To be cool when work sheet preparing

Doing the booking in cool mind is really necessary to avoid any kinds of big mistake.

Hope form next we always try to avoid not to do same mistake in future to keep secure the job as well asto enhance career.

Articles are published by the same author:

  1. The Way of Smart Merchandising
  2. Career in Merchandising: Factory vs Buying House

Line Balance and Bottleneck in Garments Production Line

Line Balance and Bottleneck in Garments Production Line
Joyankar Mojumder
Paddocks Jeans Ltd.
DEPZ, Savar, Dhaka.
Mob: 01813171408

Line balance: 
Line balance means the better allocation of the necessary tasks between the operators, which reduces waiting time.
Line balance

For line balance we have to know some data and some calculating information those are as follows: -
  1. How many operators.
  2. Operation.
  3. SMV.
  4. Performance.
  5. Potential production / hour.
  6. Hours to achieve target.
  7. Capacity.
  8. Target.
Potential production / hour: --------- x Wanted efficiency

Hours to achieve target: ------------------------------
                                        Potential Production

If SMV = 1.22
Performance = 80%
Target / Week = 2655

Then, Potential Production / Hour = ----------- X 80% = 39 pieces/hour

We know the target/week = 2655 pieces

Hours to achieve target = ------------ = 68 hrs

So Capacity is 60-68 = -8 hrs.

The upper narrow portion of a bottle is called neck (opening side) and it is an obstruction to go to the way from large portion of a bottle through narrow portion of a neck. It is a metaphorical scene of obstruction of production sector. A garments sector is a production sector and the bottleneck used here as obstruction of normal production. In a brief the bottleneck means lost production and lost profit i.e. the lowest capacity of production.

Bottleneck in the production line:
The lowest output point in the production line is called bottleneck. That is bottleneck area, where supply gathered and production goes under capacity.
Why arises bottleneck?
There are so many reasons to arise a bottleneck in the production line and it is described below.

A) Bottleneck before input in line.
  1. If issue is not supplied in time from M.C.D and sub store.
  2. If issue comes delay.
  3. Issues serial number mistake.
  4. Bundling mistake.
  5. Wrong issue supply.
  6. Pattern problem. Etc
B) Bottleneck in line:
  1. Worker selection wrong.
  2. Wrong works flow / sequence of works.
  3. Non-balance allocation of elements.
  4. Works negligence by workers.
  5. Workers absenteeism.
  6. Machine disturbances / out of order.
  7. Lack of supply.
  8. Non-serial supplies forward from workers.
  9. Color shading
  10. Quality problem.
  11. If anybody becomes sick.
Diagnostic character of bottleneck:
  • By checking counter machine: - After specific period (time to time) by checking counter machine it is easy to find out the bottleneck which counter is shown poor / lowest production. 
  • By observing serial number of supplied issue: - After checking some operators if it is found that someone is sewing / working lowest serial number of issue and it not reasonable difference with others it is defined bottleneck. 
  • By observing gathered supply: - Those areas are bottleneck areas where pile of supply is observed. 
  • By performing cycle check: - By performing cycle check we can realize bottleneck from different of time. We can realize bottleneck at a glance by making graph and it is a best and scientific way to find out the real bottleneck.
Way of reducing bottle neck: -
  1. To arrange pre- production meeting in time.
  2. To prepare layout sheet before input in the line.
  3. To check fabrics and accessories before issuing in the line.
  4. To submit the layout sheet to maintenance section minimum 2-3 days before for better preparation.
  5. To check pattern before supply in the line.
  6. To reduce excess works from workers.
  7. To select right workers for right works.
  8. To keep supply available in time.
  9. To maintain serial number.
  10. Reject garments should not forward.
  11. Supply should be forwarded after checking.
  12. To alert when bundling (maintain serial number)
  13. By improving method.
  14. By improving workers performance.
  15. By reducing sewing burst