Face to Face Layout system in Garments Sewing Line with Advantages and Disadvantages

Face to Face Layout system in Garments Sewing Line with Advantages and Disadvantages

Face to Face Layout system

Introduction

The layout is the first thing to do if you want to start a sewing line. Sewing layout is different for every individual style. A permanent layout setting is a key thing for saving manpower, machine, and transportation handling systems.


Sewing Line Layout
We did a case study on the garments sewing line. Study was two Layout systems of Garments Manufacturing. One is Straight Line layout which is currently running in our facility and another is proposed Layout 'Face to Face Layout'. If you want to know about these two Layout systems of the sewing process, here this article is only for you.

Objective:

1.       To compare running & proposed layout system

2.       To Highlight the advantages & disadvantages of the proposed layout system

Straight Line Layout system Vs Face to Face Layout system:

Category	Straight Line Layout system	Face to Face Layout system
Type of layout	Straight-line layout-Overhead material movement	Face to face layout- Zigzag material movement
Sitting arrangement	Wooden stool without any backrest	Rotating chair with backrest
No. of machine	26-28 machine/line	38-40 machine/line
Line width	Conventional- 6 feet 8 inches	Need width extension- 7 feet 2 inces
Wire arrangement	Conventional electrical connection as well as lighting	Re-arrangement as per line layout
Air compressor	Conventional air compressor line	Re-arrangement as per line layout
Bundle keeping basket	No bundle keeping basket, material movement through side table	Need bundle keeping basket for every workstation
Machine width extension	Not necessary as material movement through side table	Need machine width extension through wooden pallet as there will be no side table
Thread trimming	Manually done or there are some machine with auto trimming facility	Need auto trimming facility in every machine so that use of assistant operator become optimal
Bundle size	Big bundle size, typically 50 to 60 PCs	Bundle size need to resize, 10 to 20 PCs
Kanban/andon boards	No kanban/ andon boards in line & front	Need kanban/ andon boards in line & front

Advantages of Straight Line layout system Vs Face to Face Layout system:

Sl.	Category	Straight Line Layout system	Face to Face Layout system
1	Tracking & monitoring	Difficult to tracking & monitoring production & quality	Easy to tracking & monitoring production & quality
2	Utilization of machine	26-28 machine/line in conventional	more 10-12 machine can be used inline
3	Transportation time	Material transportation time is more	Material transportation time is less
4	Product type	Any kind of item in the production line	Basic/ small items in a production line
5	Layout doubling	Single item run in production line	Two basic items can be run in production line

Disadvantages of Straight Line layout system Vs Face to Face Layout system:

Sl.	Category	Straight Line Layout system	Face to face Layout system
1	Garments handling	Any length or size item can be handled	Only basic/ small items can be handled
2	Product variation	Any kind of product can be run online	Limited product type as long/big garments handling the issue

Expected result:

1. Transportation time reduction

2. Ergonomically designed work-station

3. Proper tracking of production & quality

4. Visual management in the production floor