Garment Sewing Department

Garment Sewing
Department
BY SAUUMYE CHAUHAN, RIYA KHANDELWAL, SAIMA ZARIN, SAKSHI SINGH & SAIRA GALHOTRA
Trafaluc by Zara
Season
Spring-Summer 2016
Style Name
EMMA4-H
Style Code
1919/081
Buyer
Zara
Country
Spain
Garment
Short Sleeve Top
Fabric
Cotton with Elastane
Front
Back
Side
Black
Colors
White
Measurement
XS
XL
Chest Size (Cms)
80
86
92
98
104
Body Length (Cms)
59
60.5
62
63.5
65
Color/Size
XS
XL
Total
Black
50
150
150
50
50
450
White
50
150
150
50
50
450
Grey
25
75
75
25
25
225
Order Quantity
Packaging
Details
Each Garment Individually Wrapped in Transparent Packets
No Of Pieces In A Carton
36
Grey
Sewing Department
The heart of a manufacturing unit
Procureme
nt of Cut
Panels
Sewing full
garment
Sewing
garment
accessorie
s
Checking
of stitched
garments
Alteration
work of
defective
garments
After receiving the garments components from

cutting section, all the garments parts are joined
and sewn sequentially
Factors To Be Considered In Sewing
Seam
Type
Stitch
Type
Sewing
Needle
Machine used
Mechanis
m
Thread
Used
The Sewing Department At American

Apparel
Pre-Sewing Process
Before the actual task of
sewing begins, there are
certain other tasks that
have to be taken care of
which can be termed as
fabric handling
functions.
Ply
separation
Distinguish
Different
Fabric Parts
Edges are
overlooked
Identification
of the seam
line
Planning of
the sewing
process
Sewing Process For A T-Shirt

A T shirt has six components
Front
Back
Neck rib or Collar
Neck tape
Two sleeves
In the figure, on the top four sections of the
garment component have been shown.
The arrows show the flow of operations and
inside the red circles operation sequence
number and name of the operations has been
written.
Join Rib
Attach
Rib
Production Systems Used In The Sewing

Department
Garmentproductionsystem isawayhowfabricisbeingconverted
intogarmentinamanufacturingsystem.
Make Through
Production
Systems
Modular
Assembly Line
Progressive
Bundle System
Unit Production
System
Make Through Production System
It is the traditional method of manufacturing in which an operator makes right through o

ne garment at a time.
One operator will do all the stages of the sewing operations of one garment
After completing it he will go for the next garment
Disadvantages
Advantages
Quick throughput time

Easier to supervise
Reduce work in progress (WIP)
Uniformity in sewing
Low productivity
High labor cost
Highly experience operator required
Suitable for highly fashion garment

and sample making
Modular Production System

The Modular Production System is expressed with team performance that allows adjustment of frequent
changes in design of clothes, sizes and order of production
The modular system works on the principle of pull-type production systems, in which the job order comes
from the last step to previous steps.
The line layout is U -shaped with garments

progressing around the line.
Each operator is cross trained on a different

portion of line (i.e. continuous operation)
depending on skills and operation complexity.
Each operator is assigned at least one

operation.
Operatives work on standing workstations.
Work In Progress (WIP) is kept to a

minimum.
Progressive Bundle System
In the progressive bundle system (PBS), the bundles of garment parts are moved sequentially from
operation to operation.
Parts of various components after being cut in the cutting room are tied with in bundles and
distributed out to the sewing section.
Bundle ticket is attached to cut parts.
One operator is expected to perform the same operation on all the pieces in the bundle.
Advantages
Cheaplaborcost
Increaseproductivity
Betterutilizationofspecialized
machine
Verylowvariationinthesewing
Lesschanceforlotmix-up
Bundletrackingisveryeasy
Disadvantages
Line balancing is difficult
Increase in WIP that increase inventory cost
System is not adaptable for short run product
ion and frequent style change
High level of management skill is require
Individual operators that work in a PBS are
dependent on one another
Unit Production System
Each production operator has a task and passes that garment on to the next person.
Normally there is only one garment between operations.
The unit of production is single garment and not bundles
Advantages
Improve productivity
Improve load time
Minimizes WIP
Improve productivity and quality monitor
Improve ergonomics (to provide ease to wor
king staff)
Keep the factory floor clean
Labor cost reduce
Disadvantage
High initial cost required
Special training required
Down time is potential problem
Sewing Machine
A sewing machine is a machine used to
stitch fabric and other materials together
with thread.
Sewing machines have been a household staple
since American inventor, Isaac Singer, successfully
mass produced a version of the machine capable of
stitching on any area on the fabric.
Sewing machines were invented during the
first Industrial Revolution
Also called an
overlock
machine,
The serger can
sew on the
edges of the
fabric only.
These
machines are
useful for
cutting and
binding fabric
edges,
stitching
stretch knits
together, and
making rolled
hems on flimsy
material.
Industrial machines
These are
open-system,
expandable
sewing
machines
Allow users to
interface with
home
computers to
use designs
outside of the
library.
Sergers
Sewing
machines
equipped with
computer chips
do not need a
cam to create a
pattern.
The built-in
stitch library is
extensive and
efficient.
These sewing
machines have
the capacity to
repeat a
designated
pattern
Computer connectable sewing machines
Electronic
circuit boards
were
incorporated
in electricpowered
sewing
machines
Allowed speed
control without
sacrificing
power and
improved
needle and
bobbin control.
Have limited
stitch selection
Computerized sewing machines
Older models
were powered
with a handcrank, a
system of
gears, and a
foot pedal.
Capable of
sewing straight
and zigzag
stitches
Electronic sewing machines
Mechanical sewing machines
Types Of Sewing Machine

Limited to
straight
stitches and
zigzags.
They are not
capable of
sewing
buttonholes
and
embellishment
s,
They are very
fast.
Stitching is
accurate and
the finished
product is
professional.
Sewing Machine Parts
Thread-guides
Stitch
regulator
Take-up lever
Tension discs/check
-spring
Needle bar
Needle
Reversing
lever
Throat plate
Machine bed
Presser foot
Types Of Sewing Machine Beds

Flat Bed Sewing Machine
Flat bed machine is used for
lock stitch or chain stitch.
It has a large working area so
material can easily pass.
Uses
It has widest application in garment
sewing in basic type
Raised Bed Sewing Machine

Features
Raised bed machine also used for
lock stitch and chain stitch formation
It facilities the assembly of pre-sewn.
Uses
It is used for fitting accessories and for
button holer
Cylinder Bed Machine

Features
Cylinder bed sewing machine is used
for producing lock and chain stitch on
the fabric.
It has increased working height (like
an arm).
Uses
It is used for sewing tubular parts,

trouser legs and sleeves.
It is also used for button sewing and
bar tacking.
Post Bed Sewing Machine

Features
Post bed sewing machine is used for
forming lock and chain stitch.
It has increased working height.
Uses
It is specially used for shoes and bags.
Off-The Arm Sewing Machine

Features
these machines require workers to feed
material along the axis of a horizontal
column
The design limits the length of the seam
sewn to the length of the column
Uses
It is useful for applications such as sleeve
and shoulder seams
Defects In Sewing
Irregular Stitch
Uneven Stitch
Needle Mark
Thread Breakage

Garment Sewing Department

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What are the different types of sewing machines discussed?

What are the different types of sewing machines discussed?

What are the different types of sewing machine beds mentioned?

What are the different types of sewing machine beds mentioned?

Garment Sewing

Short Sleeve Top

Cotton with Elastane

Chest Size (Cms)

Body Length (Cms)

Each Garment Individually Wrapped in Transparent Packets

After receiving the garments components from

Factors To Be Considered In Sewing

The Sewing Department At American

Sewing Process For A T-Shirt

Production Systems Used In The Sewing

Make Through Production System

It is the traditional method of manufacturing in which an operator makes right through o

After completing it he will go for the next garment

Quick throughput time

Reduce work in progress (WIP)

High labor cost

Highly experience operator required

Suitable for highly fashion garment

Modular Production System

The line layout is U -shaped with garments

Each operator is cross trained on a different

Each operator is assigned at least one

Operatives work on standing workstations.

Work In Progress (WIP) is kept to a

Progressive Bundle System

Bundle ticket is attached to cut parts.

Unit Production System

Normally there is only one garment between operations.

The unit of production is single garment and not bundles

Computer connectable sewing machines

Computerized sewing machines

Electronic sewing machines

Mechanical sewing machines

Types Of Sewing Machine

Sewing Machine Parts

Types Of Sewing Machine Beds

Raised Bed Sewing Machine

Cylinder Bed Machine

It is used for sewing tubular parts,

Post Bed Sewing Machine

Off-The Arm Sewing Machine

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