Industrial Engineering (IE): July 2022

What is 5S?

Those of us who work at the factory level probably know the 5S. Today's discussion for those who do not know 5S

The 5S is a Japanese method that can be followed to keep the workplace clean and tidy and increase work quality and efficiency.
Being 5S

Sort
Set in Order
Shine
Standardized
Sustain

Entering the workplace, the officer or worker wants to see the workplace in a beautiful environment. When the work place is neatly arranged, it is convenient to work and the productivity of the work is increased. On the other hand, if the work place is not properly arranged, the focus on work decreases. This is likely to greatly reduce the production of the product. The 5S is an effective strategy for arranging the workplace in a beautiful and scientific way. By applying this strategy, work efficiency can be multiplied. "5S" is a Japanese philosophy based on five pillars. The absence of one of these can completely disrupt the process of sorting out the workplace or workplace.

The pillars are:

Sort:

Sorting is the first column of 5S. Under this, first you have to choose what is needed, how much is needed and when it is needed. Things that are not needed need to be picked up and removed from the workplace.

Set in order:

The job of the second pillar is to sort things out according to the importance of the need. For example, the one that is most needed should be kept close by. The ones that need less should be kept away and marked with identification marks. Remember that in order to implement this column, it is mandatory to implement the previous column.

Shine:

This column emphasizes regular cleaning of dust and other unnecessary items. The work environment will always be clean and tidy.

Standardized:

The function of this column is to standardize the work of the first three columns and to monitor whether it is working properly. Make the above arrangements a habit.

Sustain or maintain:

The most important function of the 5S is to maintain. Maintaining the above four pillars is basically the job of this pillar. The benefits of "5S" can be reaped by making the above-mentioned tasks a habit and making the work environment suitable for work forever. For this the authorities have to take appropriate steps.

Advantages of 5S for Garments Factory:

If you properly follow 5S for our Garments industry, then we will get the following benefits:

Maximum use of the working area
To increase the comfort in the work of the workers.
Ensured the Health and Safety
Increase the Productivity
Save time, cost and storage space
Minimization of accidents & mistakes
Increases efficiency
Reduce inventory time
Reduce downtime, wastage
Good working environment
Improve company image
Optimize organization and workplace as per requirement
Everywhere Schedule and visual Standard Operating Procedure (SOP)
Everybody knows their working responsibility
Disciplined housekeeping

5S Area: Swing Line:

Things to keep in mind in the swing line area:

* Food bowls, water bottles, trolleys, plastic boxes etc. should never be kept in the sewing line.

* Necessary baskets, boxes, trolleys cuttings can be kept at the specified place.

* Operators / helpers should arrange sandals

* Sewing threads and blanks should be arranged separately according to the color of the specific rack.

* The machine needs to be maintained from time to time.

* No more than a certain quantity of bundles can be placed on the machine table as input.

* The operator has to make sure that the needle guard of the machine, machine bed, and various guides / folders are correct before the operation.

* Cut panels or bodies should never be placed on the floor.

* Instruction copies of the processes should be hung on the board in advance.

* Thread cutter and Caesar should be kept in the proper place.

* No empty thread can be placed on the machine table and no previous thread can be placed.

* No rejected body, water bottle etc. can not be placed on / under the machine table.

* Machine cover should never be placed on the machine during operation.

* Display board, production board and maintenance board of the line supervisor machine should be cleaned every day.

* Line Supervisor will fill the display board, production board appropriately from time to time.

* Multiple buyer / style cut panels and labels cannot be placed on the same table at the same time.

* Each operator will remove everything from the previous style from his machine.

* Self-operator will keep his machine at the right angle.

* Seating chairs and machine tables will never cross the signal line of the line.

* The operator of his own machine has to change the oil of his machine from time to time and clean the inside of the machine.

For implementing 5S in Apparel Industry we should follow the followings:

Need central 5S committee and section-wise subcommittee

5S Organogram and committee list as enclosed
Section-wise 5S checklist
5S display board in every section
5S audit conduct and submit a report.
Evaluate the score and take corrective action to improve in every department.
Need central 5S committee and section-wise subcommittee

Sort by:

Garments of each machine should be kept in tidy condition

The production board and maintenance board should be hung in place

IE rendering should be arranged according to the machine layout and unnecessary machines should be arranged according to the type of machine behind the line.

Cutter, Caesar should be tied with rope at the specified place

The swing thread must be kept in place

No items can be placed outside the isles mark of the line

Keep it clean:

At the end of the work the machine should be covered by the machine cover

No abandoned thread on the machine, water bottle can not be kept

The operator of his own machine will keep his machine clean

No unnecessary fabrics, cut panels, threads, accessories can be kept in the line

Idealization:

The floor cleaner will sweep the floor of the line from time to time.

At the end of each day's work the operator will complete the maintenance of his machine

Confirmation / Regular Holding:

The line supervisor will monitor the operators every day,

The line chief / floor in-charge will confirm whether the supervisor is monitoring the operators

5S can be implemented in our daily life also. Visit here to know what is operation breakdown. You can visit my website to learn more about the bulletin or breakdown of garments and different types of industrial sewing machines.

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In my industrial engineering tutorial series, I am sharing about Garments Samples it may help the Garments related persons.

What is a Garment Sample?

Garment samples are the samples that are sent for the approval of the garment buyer according to the demand of the buyer before the garments go directly to bulk production.

Types of Garment Samples:

Counter Simple:

Clothing should be made with the accessories provided by the buyer as per the specifications received from the buyer. By looking at the counter sample, the buyer will understand that the garment is being made exactly as the buyer has given the sample.

Salesman Sample:

Salesman samples are made in the same way as counter samples, usually in stores where buyers sell goods. He provides more than one piece of the sample in all the stores as a sample প্র the need to inform the buyers by displaying it in the public store, that the clothing of this item is being marketed in the store at present.

Size Set Sample

The specific size of the garment is given before the buyer makes the garment, the size sample is sent to the buyer for approval so that the size of the garment is not disturbed.

Photo Advertising Sample

The sample that is taken for doing a photo shoot is called a photo sample. With this sample, the buyer has done photoshoots with different models and stars. This is because any new design of clothing in the market is actually given to the buyers on their own website with photo samples of that clothing. Photo samples are usually taken to promote any new design on the market.

Fit Sample:

The job of this sample is to get fit approval. That is, to check whether the garment is correct and fit measurement tape has been made. There are many sizes in the same style so there is no need to make fit samples for all sizes. In this case, one or two sized samples have to be taken to get the approval from the buyer. Once approved, the rest of the production work is done accordingly.

PP Sample:

PP sample means pre-production sample. The sample that is finally made for production is called the PP sample. Since the production work will start with this sample, the sample is made with all the accessories as per the demand of the buyer.

Proto Sample:

Before purchasing one or another garment, first check the proto sample at an early stage.

In the case of proto samples in the garment industry, the buyer just wants to know if the production house is able to make the garment exactly the same. However, the correct measurement of the sample of the dress and the quality of the swing has to be prepared. So that the buyer likes to see the sample.

Size Set Sample:

These samples are made after the PP sample has been approved and before the bulk cutting has started. Samples have to be made separately to see if the measurements of all sizes are correct, then these samples are made so that the measurements and pattern sizes are correct.

Production Sample:

Orders taken from buyers collect some garments during production. Buyer can understand through him whether the quality of the product ordered by him is right or not.

TOP Sample:

TOP means "top of production" and a set of samples that taken off the line during their first production. The top of the production is the final sampling stage that occurs during production where you will see what your line will look like before you reach your customers. Be sure to bring your pre-production samples so you can test the quality of your TOP.

Shipment Sample:

When the production of the order taken from the buyer is finished, the packing and shipment is done. The buyer has to send some samples while making this shipment. This allows the buyer to understand what kind of clothing has been shipped.

GTP Sample:

GTP sample means garment packet sample. Before shipping the buyer's order, samples from bulk production at the International Third Party Testing Lab have to be checked to see if the garment shipment is actually physical stench, chemical behavior, collar fix, safety and the 'law' of the country to be shipped and the buyer's parameters.

Visit here to know what is operation breakdown. You can visit my post to learn more about bulletin or breakdown of garments. in the garment industry.

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