Operation Bulletin of a Flannel Shirt

In my industrial engineering tutorial series, I am sharing an operation bulletin of a Flannel Shirt. You can refer to this operation bulletin to learn about various operations involved and machine requirement in making Big Bear Flannel Shirt.

Operation Bulletin of a Flannel Shirt

Operation Breakdown of a flannel shirt is done by the following table. In this Operation Bulletin Operation list, Estimated time, Machine list, Hourly production target quantity at 100% and 65% efficiency are shown. The estimated time (SMV) shown in the below table will be vary according to the product method followed and machine and equipment used in actual production. So please be careful while you use the above estimated time against each operation.

Operation Bulletin of a Flannel Shirt

Operation Bulletin of a Flannel Shirt

SL.	Operation	Type of Machine	SMV	Target 100%	Target 65%
Collar Cuff &  Make
1	Collar & Collar Band & Cuff Fusing	Helper	0.50	120	78
2	Collar Mark	Helper	0.25	300	195
3	Collar Sewing	SNLS	0.40	133	87
4	Collar Edge Cut & Turn	3T O/L	0.30	200	130
5	Collar Top Stitch 1/4	SNLS	0.45	133	87
6	Collar Band Rolling	SNLS	0.30	200	130
7	Collar Band No. Match	Helper	0.25	240	156
8	Collar Band Attach	SNLS	0.50	120	78
9	Collar Band Top Stitch	SNLS	0.40	150	98
10	Collar Finishing (Edge Cut)	3T O/L	0.35	171	111
11	Cuff Rolling	SNLS	0.30	200	130
12	Cuff Marking	Helper	0.30	200	130
13	Cuff Sewing	SNLS	0.45	133	87
14	Cuff edge Cut &Turn	Helper	0.40	150	98
15	Cuff 1/4 Top Stitch	SNLS	0.50	120	78
Sleeve Make
16	Placket Placement Mark & Cut	Helper	0.30	200	130
17	Gamble Attach	SNLS	0.35	171	111
18	Gamble Tack & Raw Edge Cut	SNLS	0.30	200	130
19	Placket No. Match	Helper	0.30	200	130
20	Placket Iron	Iron	0.65	92	60
21	Placket Attach	SNLS	0.70	86	56
Back Part
22	Dart Tack	SNLS	0.30	200	130
23	Hanger Loop Make & Attach	SNLS	0.35	171	111
24	Main Label Facing Iron	Helper	0.30	200	130
25	Label Attach At Facing	SNLS	0.30	200	130
26	Facing Attach At Back Yoke	SNLS	0.30	200	130
27	Back Yoke No Match	Helper	0.30	200	130
28	Back Yoke Attach	5T O/L	0.30	200	130
29	Back Yoke Top Stitch	DNCS	0.30	200	130
Front Part
30	Facing Attach At Pocketing	SNLS	0.30	200	130
31	Pocket Bag OL	3T O/L	0.60	100	65
32	Pocket Bag Top Stitch	SNLS	0.60	100	65
33	Pocketing Attach At Side Pocket Place & Conner Cut	SNLS	0.60	100	65
34	Side Pocket Opening Top Stitch	SNLS	0.50	120	78
35	Side Pocket Tack	SNLS	0.30	200	130
36	Pair Tack	SNLS	0.30	200	130
37	Top Center Rolling	MNCS	0.35	200	130
38	Side Pocket Attach At Top Center	SNLS	0.35	171	111
39	Top center Rolling	SNLS	0.45	133	87
40	Top center Iron	Heat Seal	0.30	200	130
41	Front Pocket Placement Mark	Helper	0.40	150	98
42	Pocket Check Match	Helper	0.40	150	98
43	Pocket Marking	Helper	0.35	171	111
44	Pocket Fitting	3T O/L	0.35	171	111
45	Pocket Rolling	SNLS	0.40	150	98
46	Pocket Iron	Iron	0.65	92	60
47	Front Pocket Attach	SNLS	0.65	92	60
48	Front Pocket 1/4 Top Stitch	SNLS	0.40	150	98
49	Flap Check & Number Match	Helper	0.35	171	111
50	Flap Fusing	Steam Iron	0.30	200	130
51	Flap Mark & Sewing	Pattern Sewer MC	0.45	150	98
52	Flap Raw edge Cut &turn	3T O/L	0.40	150	98
53	Flap Top Stitch	SNLS	0.35	171	111
54	Flap 1/4 Top Stitch	SNLS	0.35	171	111
55	Flap Edge Cut & Sewing	DLM	0.30	200	130
56	Flap Attach	SNLS	0.40	150	98
57	Flap Top Stitch	SNLS	0.30	200	130
58	Patch Label Attach	SNLS	0.30	200	130
59	Front Fitting	Helper	0.30	200	130
Assemble
60	Front & Back No Match	Helper	0.30	200	130
61	Shoulder Join	SNLS	0.60	100	65
62	Shoulder Top Stitch	DNLS	0.30	200	130
63	Collar Mark	Helper	0.25	240	156
64	Collar No Match & Mark	Helper	0.30	200	130
65	Collar Attach	SNLS	0.55	109	71
66	Collar Top Stitch & Size Label Attach	SNLS	0.60	86	56
67	Sleeve No Match & Mark	Helper	0.30	171	111
68	Sleeve Attach	5T O/L	0.60	92	60
69	Arm Hole Top Stitch	DNCS	0.60	92	60
70	Care Label Attach	SNLS	0.30	200	130
71	Side Seam Join	3T O/L	0.75	86	56
72	Side Seam Top Stitch	FOA	0.60	100	65
73	Cuff No Match &  Mark	Helper	0.45	133	87
74	Cuff attach	SNLS	0.50	100	65
75	Bottom Rolling	SNLS	0.60	100	65
76	All Button Hole	BH	0.80	75	49
77	All Bartack	B/T	0.50	120	78
78	Thread Cut	Helper	0.60	100	65
	Total		32.25

Full form of Machine Name:

In the above table short name of sewing machines are written. Followings are the abbreviation of those short machine codes.

SNLS - Single needle lock stitch

DNLS - Double needle lock stitch

DNCS - Double needle chain stitch

DLM - Single needle lock stitch Edge Cutter

FOA - Feed of the Arm

MNCS - Multi needle chain stitch

3T O/L - 3 thread over lock

5T O/L - 5 thread over lock

Heat Seal - Heat Seal

Pattern Sewer MC - Pattern Sewer Machine

BT - Bartack

BH - Button Hole

Operation Breakdown makes our work easy to set up a production line in the apparel industry. We can easily manage machine and operator requirements for any sewing line by this. But it is necessary to do an operation breakdown to prepare a machine layout and line balancing by industrial engineering (IE). 

Flannel Shirt Bottom hem. She has taken 20 seconds only to complete this process. Please watch video .

How Flap Sewing with a Pattern Sewer Machine Reduces Marking Helpers and Cost:

Please see the video below -

Check out my YouTube channel "Sewing Engineering'. Be sure to like, comment and share. Subscribe and hit the bell icon for more innovative sewing techniques in the next video.

1: Traditional Method  

Show a worker manually marking and sewing flaps.

Explain:

"In traditional methods, marking each flap manually requires extra helpers, time, and effort."

2: Using Pattern Sewer Machine  

Show the pattern sewer machine stitching the flap directly onto the fabric.

Explain:

"With a pattern sewer machine, the stitching is precise and automated, eliminating the need for manual marking helpers."

3: Benefits Highlight  

Display close-up shots of the machine working smoothly.

Bullet points appear on the screen:

       "Reduces labor costs"

       "Speeds up production"

       "Ensures uniformity and quality"

Summary:

By adopting the pattern sewer machine for flap sewing, manufacturers can save time, reduce costs, and improve product quality. It's a smart move for efficient production.

I have published an article 24 Effective Strategies to Enhance Efficiency in the Garment Industry, which is a very helpful post.

You can visit my post to learn more. Visit here to know What is a sewing needle? in the garment industry. Industrial Sewing Machine play a pivotal role in various sectors of manufacturing, from apparel production to automotive components. Do you want to learn more about "Industrial Sewing Machine"?

Thank you for your patience reading. Please, Share this article with others. It will inspire me to write more about this. 

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