This document summarizes a study comparing a new panel replacement system to an existing system at a garment factory. Key findings of the study include: 1) The new system saves 0.001 kg of fabric per piece and could save 50 kg of fabric per day, reducing costs. 2) Rejection rates due to fabric faults would fall from 1.54% to potentially 0% with the new system, saving over 4,000 pieces of garments per month. 3) The new system requires 12 additional workers at a cost of $1,200 per month but increased earnings from fabric and production savings would be over $21,500 per month.

1. SQUARE Fashions Ltd - 2
Mohammed Nazmul Hasan
Manager – Industrial Engineering
SQUARE Fashions Ltd - 2
Prepared By

2. Date
Syste
m
Exp
erim
ent
no
Fabric
No
of
dock
et
Lay
quant
ity
Marker
pcs.
Total
cutting
quantit
y in
.pcs.
Actual
cuttin
g
quanti
ty
Lost
%
Marker
length in
mtr
Total
weight of
the fabric
Used
weigh
t in
Kg
Fabri
c for
re cut
in Kg
Wast
in kg
Wast
e%
Reje
ctio
n
.pcs.
In
cutt.
Cuttin
g
Reject
ion %
Requ
ired
time
Requir
ed
manp
ower
Reeq
uired
fabric
/.pcs.
Requi
red
time/.
pcs.
10/5/20
14
New 1 Fleece 3 120 7,7,3,1 790 790 0%
4.61-4.61-
2.1-1
305.60 283.00 10.52 11.55 3.78% 18 2.28% 893 13 0.387 1.130
12/5/20
14
New 2
S/J
(Lycra)
1 80 8 640 640 0% 5.45 129.06 123.20 4.96 0.9 0.70% 33 5.16% 390 13 0.202 0.609
13/5/20
14
New 3
Pique
(PK)
1 90 6 540 540 0% 4.18 126.37 119.70 6.17 0.5 0.40% 16 2.96% 295 12 0.234 0.546
18/5/20
14
New 4
Single
jersey
1 96 3 288 288 0% 3.75 69.88 65.28 4.00 0.6 0.86% 10 3.47% 265 13 0.243 0.920
Subtotal 6 386 2258 2258 0% 630.91 591 25.65 13.55
2.15
%
77 3.41%1843 13 0.279 0.816
10/5/20
14
Existin
g
1 Fleece 3 120 7,7,3,1 728 697 4.26%
4.61-4.61-2-
1
274 264.00 0.00 10.5 3.83% 31 4.26% 759 12 0.393 1.089
12/5/20
14
Existin
g
2
S/J
(Lycra)
1 84 8 672 631 6.10% 5.45 131.06 129.00 0.00 1.7 1.30% 41 6.10% 326 12 0.208 0.517
13/5/20
14
Existin
g
3
Pique
(PK)
1 90 6 540 522 3.33% 4.18 123.25 122.00 0.00 1.75 1.42% 18 3.33% 275 12 0.236 0.527
18/5/20
14
Existin
g
4
Single
jersey
1 87 3 261 252 3.45% 3.75 59.22 57.00 0.00 1.8 3.04% 9 3.45% 220 12 0.235 0.873
Subtotal 6 381 2201 2102
4.71
%
587.53 572 0.00 15.75
2.68
%
99 4.50%1580 12 0.280 0.752
Study Details

3. Consumption & Manpower Comparison
System
Req. fab
per pcs
Rejectio
n %
Waste%
New 0.279 3.41 2.15
Existing 0.280 4.5 2.68
System Man req.
Time for 100
pcs
New 13 82
Existing 12 75
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
Req. fab per
pcss
Rej % Wast%
.279
3.41
2.15
.280
4.5
2.68
New Existing
0
10
20
30
40
50
60
70
80
90
Man req Time for 100 pcss13
82
12
75
New Existing

4. Comparison study in sewing
line
Total
pcs
Total
rejectio
n
Fabric
rejectio
n
Fabric rej.
%
Total rej %
Panel
short in
bundle
Short%
Panel
excess
in
bundle
Excess
%
New system 540 15 6 1.11% 2.78% 3 0.56% 9 1.67%
Existing
system
519 18 8 1.54% 3.47% 5 0.96% 15 2.89%
0
0.5
1
1.5
2
2.5
3
3.5
Total rej. In sewing
%
Fabric rej. % Panel Short % Panel Excess%
2.78
1.11
0.56
1.67
3.47
1.54
0.96
2.89
New system Existing system

5. Comparison between New & Existing
System
In existing system 587.53 kg fabric
used to make ready 2102 pcs
input for sewing line which
consumption is 0.280
(587.53/2102) kg per piece.
In new system 630.91 kg fabric
used to make ready 2258 pcs input
for sewing line which consumption
is 0.279 (587.53/2102) kg per
piece.
Consumpti
onExisting
System
New System
We can save (0.280-0.279) 0.001 kg per piece from new system. If
cutting production is 50,000 per day, fabric will save (50,000*0.001) 50
kg per day. So we can save (26*50) 1560 kg fabric per month to apply
new panel replace system in our cutting section which cost is
(1300*$8*75) TK 7,80,000.
Result

6. In existing system we found 1.54%
complete garment rejection for fabric
fault in cut panel which is not
replaced from the cutting.
Comparison between New & Existing
System
In new system we found 1.11%
complete garment rejection for fabric
fault in cut panel but in new system can
be 0% complete garment rejection for
fabric fault because all rejection panel
will be replaced from cutting before
input sewing line.
Garment Rejection
Existing
System
New System
We can save garment rejection (1.54 - 1.11) 0.43%. Cutting
section input 40,000 pieces in sewing line per day, new system
will save (50,000*0.43%) 172 pieces garments per day and
monthly (172*26) 4472 pieces which cost is (4472*$4*75) TK
13, 41,600. As per new system it can be 0% which cost is
(50,000*1.54%) (770*26) (20020*$4*75) TK 60,06,000.
Result

7. Comparison between New & Existing
System
There are 12 manpower using per
cutting table in existing system
In new system we need (12+1)
additional manpower to support
panel replace section.
Manpower
Existing
System
New System
We are using 4 cutting table in every floor which is total (4*3)12 tables.
So we need additional 12 manpower for new system which monthly
salary will be maximum (10,000*12) TK 1,20,000.
Result

8. Comparison between New & Existing
System
There are 12 manpower using per
cutting table in existing system
Total Earnings
We can earn from new system (7,80,000 +
13,41,600)-1,20,000 monthly TK 21,57,600 and
(21,57,600*12) annually TK 2,58,91,200. As
per new system we can earn more (7,80,000 +
60,06,000)-1,20,000 monthly TK 66,66,000 and
(66,66,000*12) annually TK 7,99,92,000.
New System

9. Reduce sticker mistake in
sewing line
Other value adding benefit comparing
New & Existing System
Quality
New System
Control garments shading
problem in sewing line
Sticker mistake found in sewing
line
Existing
System
Shading garments found in
sewing line

10. Ensure full bundle quantity in
sewing line
Other value adding benefit comparing
New & Existing System
Sewing Production
New System
No extra hassle in sewing
production
Panel missing found in sewing
line
Existing
System
Sewing production interrupt for
sticker mistake & shading
problem
Ensure quick input supply for
sewing line
Input supply delay

11. Most of the buyer provide extra
mark for this system which will
help us to get highest mark in
technical audit.
Other value adding benefit comparing
New & Existing System
Customer
New System
We are losing mark from buyer
in technical audit
Existing
System

12. Prepared By
Dy. Manager – Industrial
Engineering
SQUARE Fashions Ltd - 2
THANK
YOU