Garment Sewing

Department
BY SAUUMYE CHAUHAN, RIYA KHANDELWAL, SAIMA ZARIN, SAKSHI SINGH & SAIRA GALHOTRA
Trafaluc by Zara
Season Spring-Summer 2016 Style Name EMMA4-H Style Code 1919/081

Buyer Zara Country Spain Garment Short Sleeve Top

Front Back Side Fabric Cotton with Elastane

Colors Black White Grey

Measurement XS S M L XL

Chest Size (Cms) 80 86 92 98 104

Body Length (Cms) 59 60.5 62 63.5 65

Order Quantity
Color/Size XS S M L XL Total

Black 50 150 150 50 50 450

White 50 150 150 50 50 450
Grey 25 75 75 25 25 225
Packaging
Details Each Garment Individually Wrapped in Transparent Packets
No Of Pieces In A Carton 36
Sewing Department

The heart of a manufacturing unit

Sewing Alteration
Procureme Checking
Sewing full garment work of
nt of Cut of stitched
garment accessorie defective
Panels garments
s garments

After receiving the garments components from

cutting section, all the garments parts are joined
and sewn sequentially
Factors To Be Considered In Sewing

Seam Stitch Sewing Needle Thread

Type Type Machine used Used
Mechanis
m
The Sewing Department At American
Apparel
Pre-Sewing Process Ply
separation

Before the actual task of Distinguish

Different
sewing begins, there are Fabric Parts

certain other tasks that

have to be taken care of Edges are
overlooked
which can be termed as
fabric handling
functions. Identification
of the seam
line

Planning of
the sewing
process
Sewing Process For A T-Shirt
Join Rib
A T shirt has six components
• Front
• Back Attach
Rib
• Neck rib or Collar
• Neck tape
• Two sleeves

In the figure, on the top four sections of the

garment component have been shown.
The arrows show the flow of operations and
inside the red circles operation sequence
number and name of the operations has been
written.
 Production Systems Used In The Sewing
Department
Garment production system is a way how fabric is being converted
into garment in a manufacturing system.

Make Through

Production
Systems Modular
Progressive
Bundle System
Assembly Line
Unit Production
System
Make Through Production System
• It is the traditional method of manufacturing in which an operator makes right through o
ne garment at a time.
• One operator will do all the stages of the sewing operations of one garment
• After completing it he will go for the next garment
Disadvantages
• Low productivity
Advantages
• High labor cost
• Quick throughput time
• Highly experience operator required
• Easier to supervise
• Suitable for highly fashion garment
• Reduce work in progress (WIP) and sample making
• Uniformity in sewing
Modular Production System
The Modular Production System is expressed with team performance that allows adjustment of frequent
changes in design of clothes, sizes and order of production

The modular system works on the principle of pull-type production systems, in which the job order comes
from the last step to previous steps.

• The line layout is U -shaped with garments

progressing around the line.
• Each operator is cross trained on a different
portion of line (i.e. continuous operation)
depending on skills and operation complexity.
• Each operator is assigned at least one
operation.
• Operatives work on standing workstations.
• Work In Progress (WIP) is kept to a
minimum.
Progressive Bundle System
• In the progressive bundle system (PBS), the bundles of garment parts are moved sequentially from
operation to operation.
• Parts of various components after being cut in the cutting room are tied with in bundles and
distributed out to the sewing section.
• Bundle ticket is attached to cut parts.
• One operator is expected to perform the same operation on all the pieces in the bundle.

Advantages Disadvantages
• Cheap labor cost • Line balancing is difficult
• Increase productivity • Increase in WIP that increase inventory cost
• Better utilization of specialized • System is not adaptable for short run product
machine ion and frequent style change
• Very low variation in the sewing • High level of management skill is require
• Less chance for lot mix-up • Individual operators that work in a PBS are
• Bundle tracking is very easy dependent on one another
Unit Production System
• Each production operator has a task and passes that garment on to the next person.
• Normally there is only one garment between operations.
• The unit of production is single garment and not bundles

Advantages Disadvantage
• Improve productivity • High initial cost required
• Improve load time • Special training required
• Minimizes WIP • Down time is potential problem
• Improve productivity and quality monitor
• Improve ergonomics (to provide ease to wor
king staff)
• Keep the factory floor clean
• Labor cost reduce
Sewing Machine
A sewing machine is a machine used to
stitch fabric and other materials together
with thread.

Sewing machines have been a household staple

since American inventor, Isaac Singer, successfully
mass produced a version of the machine capable of
stitching on any area on the fabric.

Sewing machines were invented during the

first Industrial Revolution
Types Of Sewing Machine

Computer connectable sewing machines

Mechanical sewing machines

Electronic sewing machines

Computerized sewing machines

Sergers

Industrial machines
• Older models • Electronic • Sewing • These are • Also called an • Limited to
were powered circuit boards machines open-system, overlock straight
with a hand- were equipped with expandable machine, stitches and
crank, a incorporated computer chips sewing • The serger can zigzags.
system of in electric- do not need a machines sew on the • They are not
gears, and a powered cam to create a • Allow users to edges of the capable of
foot pedal. sewing pattern. interface with fabric only. sewing
• Capable of machines • The built-in home • These buttonholes
sewing straight • Allowed speed stitch library is computers to machines are and
and zigzag control without extensive and use designs useful for embellishment
stitches sacrificing efficient. outside of the cutting and s,
power and • These sewing library. binding fabric • They are very
improved machines have edges, fast.
needle and the capacity to stitching • Stitching is
bobbin control. repeat a stretch knits accurate and
• Have limited designated together, and the finished
stitch selection pattern making rolled product is
hems on flimsy professional.
material.
Sewing Machine Parts Thread-guides

Stitch
regulator
Take-up lever

Tension discs/check
-spring

Needle bar

Needle Reversing
lever

Throat plate
Machine bed
Presser foot
Types Of Sewing Machine Beds
Flat Bed Sewing Machine
• Flat bed machine is used for
lock stitch or chain stitch.
• It has a large working area so
material can easily pass.
Uses

It has widest application in garment

sewing in basic type
Raised Bed Sewing Machine

Features

• Raised bed machine also used for

lock stitch and chain stitch formation
• It facilities the assembly of pre-sewn.

Uses

It is used for fitting accessories and for

button holer
Cylinder Bed Machine

Features

• Cylinder bed sewing machine is used

for producing lock and chain stitch on
the fabric.
• It has increased working height (like
an arm).

Uses
• It is used for sewing tubular parts,
trouser legs and sleeves.
• It is also used for button sewing and
bar tacking.
Post Bed Sewing Machine
Features

• Post bed sewing machine is used for

forming lock and chain stitch.
• It has increased working height.

Uses
It is specially used for shoes and bags.
Off-The Arm Sewing Machine

Features
these machines require workers to feed
material along the axis of a horizontal
column
The design limits the length of the seam
sewn to the length of the column

Uses
It is useful for applications such as sleeve
and shoulder seams
Defects In Sewing

Irregular Stitch Needle Mark

Uneven Stitch Thread Breakage