What is operation breakdown in the garment industry?

Each piece of garment has some operation on different parts. There are many operators in this workplace who perform single operations. All these factors decide that parts of the garment can be sewed at the station. The most important section of the garment industry is the sewing section. So it is very important to find out the operation breakdown for each garment according to its design and style.

Operation Breakdown Meaning:

A breakdown is a list of things that work by elements in the apparel industry by industrial engineering. One  garment consists of some parts and by number of stitching and non stitching  activities. Breakdown means writing down all the parts and all the processes or operations one after another to  complete the garment and type of machines to each and every process. 

To prepare the estimate of SMV of  the whole garment then write down the estimate SMV of every process/operation.  After calculating the sum of all individual SMV we will get the SMV of the whole garment.

 

Importance of operation breakdown:

• To understand garment construction - like type of stitch/seam,  type of machine.
• To prepare an operation bulletin the first step is doing operation breakdown of the garment.
• Requirement of sewing machines and equipment to make the garment.
• Requirement of worker to make the garment.
• To learn about additional guides, folders and attachments
• Operation breakdown reduces our unnecessary work and time
• Operation breakdown is followed by sewing floor management

 

Advantages of Operation Breakdown:

• We can see all the activities of the garments at once.
• We can predict the difficulties of performing critical operations
• We can create the layout in a simple, easy and less time consuming way
• We can easily choose the right operator for the right process.
• We can easily select the correct method for the process.
• We will know the quantity and types of machines for making the required
• garments according to the target plan.

 

Operation breakdown method:

• The floor management (executive, technician and work-study officer) should
  sit together to make the breakdown.
• Technician assembles the broken parts one by one.
• Then the work-study officer writes down the SMV of those operations
• and take the approval.

The operations are written in sequence of the actual process flows to make the garment layout for the line/floor. One sample operation breakdown of swim short is shown in the below:

Formula to set the 100% target:

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

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

In an operation breakdown, we listed the different parts and components of the garment, sewing and machine types and the labor required to make the garment. It helps us to increase productivity and efficiency.

You can visit my post to learn more about Operation bulletin of different garments. I have shared the Operation bulletin of Shirt , Operation Breakdown of Boys Swimwear and Denim Jacket. I hope it will be helpful to you. 

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