Operation Breakdown of Ladies Dungaree

Dungaree is often compared to denim 5 pocket, but there is a difference. It has bib with big chest pocket and  suspender. In my industrial engineering tutorial series, I am sharing an Operation Breakdown of Ladies Dungaree or Operation Breakdown of Ladies Overall. You can refer to this operation bulletin to learn about various operations involved, SMV and machine requirements in making Ladies Dungaree in the garment industry. It is also known as a overall.

Here I describe the operation breakdown of Ladies Dungaree or Overall with SMV and Machine name.

Operation Breakdown of Ladies Dungaree

Operation Breakdown of Ladies Dungaree is done by the following table. In this operation bulletin process list, estimated time, machine name, hourly production target quantity at 100% and 65% efficiency are shown. The estimated time (SMV) shown in the below table will 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 Breakdown of Ladies Dungaree

SL.	Operation	Type of Machine	SMV	Target 100%	Target 65%
Front Part
1	Front Rise Overlock	3TH OL	0.25	240	156
2	Front Rise Sewing	SNLS	0.25	240	156
3	Front Rise Top Stitch (1/16)	SNLS	0.30	200	130
4	J-Stitch Placement Mark	Manual	0.25	240	156
5	J-Stitch	DNLS	0.25	240	156
6	Front Rise Top Stitch (1/4)	SNLS	0.25	240	156
7	Pocket Facing Overlock	3TH OL	0.30	200	130
8	Pocket Facing Attach(Big)	SNLS	0.30	200	130
9	Pocket Facing Attach(Small)	SNLS	0.30	200	130
10	Pocket Number Match	Manual	0.25	240	156
11	Pocket Sewing	SNLS	0.40	150	98
12	Pocket Opening Top Stitch	DNLS	0.35	171	111
13	Pocket Tack	SNLS	0.40	150	98
14	Pocket Bag Closing & Turn	3TH OL	0.45	133	87
15	Pocket Bag Top Stitch (1/4)	SNLS	0.40	150	98
16	Single Fly Overlock	3TH OL	0.20	300	195
17	Single Fly Attach	SNLS	0.25	240	156
18	Single Fly Top Stitch (1/16)	SNLS	0.20	300	195
19	Loop Attach	SNLS	0.25	240	156
20	Front Bib Dart Sewing	SNLS	0.25	240	156
21	Front Bib Dart Top Stitch .	FOA	0.20	300	195
22	Front Bib Facing Sewing	SNLS	0.20	300	195
23	Front Bib Rolling	SNLS	0.60	100	65
24	Front Bib Top Stitch (1/16)	SNLS	0.50	120	78
25	Front Bib Top Side Rolling	SNLS	0.25	240	156
26	Bib Pocket Rolling	DNLS	0.20	300	195
27	Bib Pocket Iron & Number Match	IRON	0.40	150	98
28	Pocket Attach	SNLS	0.30	200	130
29	Pocket Top Stitch (1/4)	SNLS	0.25	240	156
30	Bib Number Match	Manual	0.25	240	156
31	Bib Tack With Body	SNLS	0.40	150	98
32	Waist Belt Number Match	Manual	0.25	240	156
33	Waist Belt Attach	KANSAI	0.50	120	78
34	W/B Raw edge Cut & Trimming	Manual	0.30	200	130
35	Mouth Tack	SNLS	0.30	200	130
Back Part
36	Back Yoke Sewing	SNLS	0.25	240	156
37	Back Yoke Top Stitch	FOA	0.20	300	195
38	Back Rise Join	FOA	0.25	240	156
39	Pocket Rolling	SNLS	0.25	240	156
40	Pocket Number Match	Manual	0.25	240	156
41	Pocket Iron	IRON	0.45	133	87
42	Pocket Attach	SNLS	0.70	86	56
43	Waist Placement Mark	Manual	0.20	300	195
44	Pocket Bartack	BT	0.20	300	195
45	Double Fly Tack	SNLS	0.20	300	195
46	Double Fly Attach	SNLS	0.20	300	195
47	Loop Make & Cut	FL	0.39	154	100
48	Loop Attach	SNLS	0.40	150	98
49	Back Bib Dart Sewing	SNLS	0.25	240	156
50	Back Bib Dart Top Stitch	FOA	0.25	240	156
51	Back Bib Facing Edge Overlock	3TH OL	0.20	300	195
52	Back Bib Facing Rolling	SNLS	0.20	300	195
53	Label Placement Mark	Manual	0.20	300	195
54	Main & Size Label Attach	SNLS	0.40	150	98
55	Suspender Mark & Cut	Manual	0.35	171	111
56	Suspender Attach	SNLS	0.35	171	111
57	Back Bib Facing Number Match	Manual	0.25	240	156
58	Back Bib Facing Sewing	SNLS	0.30	200	130
59	Back Bib Rolling	SNLS	0.60	100	65
60	Back Bib Top Stitch (1/16)	SNLS	0.45	133	87
61	Bib Number Match	Manual	0.25	240	156
62	Bib Tack With Body	SNLS	0.40	150	98
63	Waist Belt Number Match	Manual	0.25	240	156
64	Waist Belt Attach	KANSAI	0.50	120	78
65	W/B Raw edge Cut & Trimming	Manual	0.30	200	130
66	Mouth Tack	SNLS	0.30	200	130
Assemble
67	Back Front Number Match	Manual	0.25	240	156
68	Inseam Join	5TH OL	0.45	133	87
69	Inseam Top Stitch	FOA	0.40	150	98
70	Bottom Decoration Stitch	DNLS	0.30	200	130
71	Side Seam Join	5TH OL	0.65	92	60
72	Side Seam Decoration Stitch	SNLS	0.45	133	87
73	Bottom Rolling	SNLS	0.41	146	95
74	Care Label Attach	SNLS	0.20	300	195
75	Loop Bartack	BT	0.60	100	65
76	Bib Pocket, Front Pocket & Fly Bartack	BT	0.45	133	87
77	Side Seam Bartack	BT	0.12	500	325
78	Waist Key Hole	EH	0.45	133	87
79	Suspender Edge Overlock	3TH OL	0.15	400	260
80	Final Trimming	Manual	0.70	86	56
	Total		26.07

Requirement of Machine Name and full name:

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

SNLS - Single needle lock stitch

DNLS - Single needle lock stitch

3TH O/L - 3 Thread over lock

5TH O/L - 5 Thread over lock

FOA - Feed of the Arm

Kansai - Multi Needle Chain Stitch Machine

FL - Flat Lock

BT - Bartack

EH - Eyelet Hole

Manual - Helper

How to set the target per hour in the Sewing line of the Garment Factory?

Formula to set the 100% target:

Daily Target = (Worker x Working hour x 60/ SMV) x efficiency %

Basic Pitch Time (BPT) =Total SMV / Total Manpower

You can set your target based on your Floor Efficiency or Plan Efficiency.

Example:

Worker = 75

Working Hour = 10

Plan Efficiency = 65%

Then Daily Target is 1120

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) in the apparel industry. 

You can visit my post to learn more. Visit here to know what operation breakdown is in the garment industry. You can check my previous post boys swimwear breakdown.

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