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Ways to solve issues faced by traditional jacket manufacturing industry

Bangladesh’s apparel industry, from the very beginning, was well-known for making basic knitwear items that tended to fetch very low prices from foreign retailers and brands. However, nowadays, apparel manufacturers are willing to make high-end items. Along these lines, some apparel manufacturers turned into suit-making businesses – as higher margin in suit segment drawing entrepreneurs’ attention.

Ways to solve issues faced by traditional Jacket manufacturing industry
Figure 1: The traditional Jacket manufacturing industry has issues such as low efficiency, longer lead time, high rework & re-work, poor line balance, low style shift flexibility, etc.

A coat or jacket is an outerwear garment, worn on the upper body up to mid-stomach length for warmth or insulation or fashion. Coats typically have full sleeves and are open down the front, generally closed by means of buttons, zippers. In this article, we will share a list of raw materials used for making coats (for men or women).

The global coats and jackets market size was estimated at USD 44.03 billion in 2022 and is expected to expand at a compound annual growth rate (CAGR) of 5.70% from 2022 to 2026. Comparatively speaking, China generates the majority of revenue ($9,173.00m in 2022). By 2026, volume in the Coats & Jackets market is estimated to reach 812.7 million units and predicted to rise by 10.3% in volume in 2023.

The traditional Jacket manufacturing industry has issues such as low efficiency, longer lead time, high rework & re-work, poor line balance, low style shift flexibility, etc.

Here we will highlight some problem areas and discuss how we can resolve these issues.

Cutting section

Reasons:

  • Cut panel does not match with pattern
  • Bundling mistake
  • Numbering mistake
  • No cutting as per shade band
  • Cutting section are not achieving the cutting plan
  • Cut mark missing
  • Wrong size, colour and PO cutting
  • EMBO, print, rib, laser CWS if cutting supply not send on time
  • If we do not relax the fabric before cutting if needed
  • If layer paper information is wrong
  • If we do not follow fabric inspection report, shrinkage report, shade band report before cut

Solutions:

  • Cut as per marking line
  • Bundling should be done as per ratio/mark
  • Follow size and number according to plan
  • Cut as per approval shade
  • Follow cut mark mention as ‘marker’
  • Follow cutting plan
  • Send cut panel to other department before input 3 to 4 days minimum
  • Must have to relax fabric if needed
  • Maintain carefully
  • Before cut need approval form QA

Merchandising section

Reasons:

  • Wrong materials information given to production plan
  • Non update technical file given to production floor
  • Update comments not given to production floor
  • Swatch card mistake
  • Wrong materials supply to production store
  • If we cannot arrange materials on time as per plan
  • If we cannot arrange all materials approval on time

Solutions:

  • Need actually materials ETA given to production plan
  • Need to supply update file.
  • Need to supply update comments
  • Make swatch with original materials
  • Correct materials supply to line
  • Arrange on time materials before input production
  • Arrange materials approval before input line

Store section

Reasons:

  • IN accuracy of inventory report
  • Wrong materials supply to production line
  • Wrong materials information given to merchandiser

Solutions:

  • Inventory report should be perfect
  • Before issue materials must check with approval swatch
  • Correct information given

Pattern Section:

Reasons:

  • Wrong pattern supply to production/cutting section
  • If pattern is not checked before cutting
  • If not following update measurement spec/comments
  • If grading mistake
  • On time pattern supply to cutting or production floor
  • If not added shrinkage percentage in pattern

Solutions:

  • Check pattern before issue to cutting section
  • Check pattern before issue to cutting section
  • Follow update measurement spec before cutting
  • Size wise grading check carefully
  • If require must added shrinkage percentage in pattern
Ways to solve issues faced by traditional Jacket
Figure: A coat or jacket is an outerwear garment, worn on the upper body up to mid-stomach length for warmth or insulation or fashion. 

QA section:

Reasons:

  • If update measurement spec/Comments/Tech pack are not followed
  • If daily QA check system, measurement, styling etc. are not followed
  • If we do not allow before and after wash shrinkage measurement
  • If fabric inspection report, shrinkage report, shade band report are not followed before cut
  • If update sample is not followed
  • If we do not check sewing tension, skip/broken

Solutions:

  • QA team will follow update tech pack, comments, swatch
  • Daily process check, measurement check, styling check, colour check needs to have QA system
  • Need to check shrinkage report
  • Need to check
  • Follow update sample
  • Random need to check machine tension, skip, broken etc.

Production section:

Jackets have one of the longest sewing lines ranging from 70 to 80 sewing machines per line with part preparation and final assembly all together in a single sewing line and producing 400 to 600 jackets per 8 hours depending on the style. The reason for having such long sewing lines is due to the complexity in construction requiring too many sewing operations to construct a jacket and we have to break it down in the simplest form for the operator to make it efficient.

Reasons:

  • If we miss proper break down before lay out
  • If there is no proper line balance as per line graph
  • Size mistake, number mistake,
  • Accessories attach mistake
  • Proper line balance as per obs time
  • Reject control not properly
  • Wrong operator selection
  • Wrong attachment like feed dog, needle plate, pressure foot, etc.
  • Absenteeism balance not properly
  • Correct plan for correct line
  • Over input

Solutions:

  • Make a layout and breakdown before start input
  • After graph line must have to balance
  • Avoid size and numbering mistake inline.
  • Accessories attach base on approve swatch card
  • Select good operator for critical operation
  • Select wright operator for wright process
  • Wright attachment select
  • Absenteeism balance base on line graph
  • Select correct order for correct line
  • Control WIP

Others:

Reasons:

  • Factory Environment
  • Absenteeism
  • Factory management policy
  • Training
  • Proper production plan

Solutions:

  • Make factory a good workable condition

Problem is not a bad thing, if knowing your problems can make you build the ability to face the problem with solutions accordingly. By understanding the problems, you can work for the better solution that keeps you away from the frequent problems.

If anyone has any feedback or input regarding the published news, please contact: info@textiletoday.com.bd

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