Different Types of Sewing Line Layout in Garment Industry

Different Types of Sewing Line Layout in Garment Industry

Swati Wadekar
Executive IE officer at Pratibha Syntex, Indore
Email: swatiw1110@gmail.com

Introduction:
When we talk about the swing line layout, it means arranging the sewing machine and workstations in an assembly to optimize the production process of sewing product and showing the flow of the work from start to end. It involves planning the placement of machines, tables and workers for efficient workflow, sequence of operations, material flow, and ergonomics to enhance productivity and quality in the sewing process.

Why is Sewing Line Layout Prepared in Garment Manufacturing?
With the help of line layout you can set the line for a new order in the least time. From the layout, you will get the exact requirement of machines, manpower and equipment so production team can be better prepared. Style change over time can also be reduced by preparing a detailed line layout and doing line set up based on the line layout.

Objectives of Designing a Suitable Sewing Line Layout:
The object of the sewing line layout is to assure that all workstations and equipment is rationally placed for the smooth work flow and greatest efficiency.

To optimize equipment layout, consider:

1. Plan aisles, entry, and exit points.
2. Utilize the three-dimensional workspace efficiently.
3. Prioritize comfort in the working environment.
4. Detail the primary flow in the layout.
5. Ensure flexibility for changes in manufactured products.
6. Keep the layout simple for easy monitoring.
7. Minimize material transfers and use the shortest routes in sewing lines, aligning them with the manufacturing flow by arranging workstations close to each other.
8. Creating a workspace conductive to human comfort and safety.
9. Implementing effective communication and information flow system within the line layout

Software Used to Create a Customized Layout:
These are some of the few software which is being used to produce a customized layout as per the production requirement and to produce maximum efficiency.

• ALDEP (Automated layout design program)
• CORELAP (Computerized relationship layout planning)
• CRAFT (Computerized related allocation of facilities technique)
• CALP (Computer Aided layout planning)

Types of Sewing Line Layout:
There are some types of sewing lines environment manufacturing.

a) Straight line layout:
Straight line layout is most common method of arranging machines where all sewing machines or workstations form a straight line. This layout helps for the smooth garment movement from one machine to another machine without any unnecessary turns or hurdles. In this layout each worker performs a specific task. This layout is designed to minimize material handling, reduce waiting times, and enhance the overall workflow. Managers or supervisors can easily oversee things because of its linear structure.

b) U-Shaped Layout:
A U-shaped layout in garment manufacturing refers to organizing workstations and equipment in the shape of a “U” to enhance workflow efficiency. This type of layout facilitates effective communication between workstations to enhance coordination and collaboration among workers. This setup reduces unnecessary walking and movement by positioning workstations within easy reach, enabling workers to focus on their tasks without excessive travel.

c) L-Shaped Layout:
An L-shaped layout in garment manufacturing typically involves arranging work stations in the shape of an “L” to optimize workflow. This Layout arranges sewing machines or workstations in two perpendicular lines forming a right angle-like shape (L). This layout optimizes floor space utilization while maintaining good communication flow between work stations. The layout is designed to minimize unnecessary movement of materials and products. This can reduce production time and labor costs.

d) S-Shaped Layout:
An S-shaped layout refers to an arrangement of workstations that forms the shape of the letter ‘S’. The S-shaped layout facilitates a continuous flow of materials and products, reducing bottlenecks and interruptions in production. In this type of layout Materials enter at one end of the ‘S’ and the final stage is often positioned at the other end of the ‘S’ where finished products are inspected, packaged, and prepared for shipping. The layout can be adapted to different production scales and product types, making it versatile for various garment manufacturing setups.

e) Cellular Layout:
In garment manufacturing, cellular layout is a production system where Machines and workstations are grouped based on the operations they perform and allowing workers to focus on specific tasks and become specialized. This layout can be arranged in various configurations, like as straight line layout, U-shaped layout, L-Shaped layout or S- Shaped layout depending on the product’s requirements. In this layout we can move or change the way things are set up. Supervision and control are focused within each cell, making it easier for managers and supervisors to monitor production processes, identify bottlenecks, and implement improvements. In this layout Cross-training becomes more manageable and Employees in a cell work closely together, promoting communication and collaboration.

f) Modular layout:
In lean manufacturing, the optimization of material flow and machine utilization is very important for enhancing efficiency. To achieve this, sewing machines are strategically arranged, deviating from conventional U-shaped or straight-line layouts. Instead, a specialized arrangement is implemented, often referred to as a modular layout. In this layout, sewing machines are positioned to facilitate a collaborative and streamlined workflow. Multiple sewing machines are grouped in a manner that accommodates operators working from a single chair. This layout aims to minimize material transportation distances, reduce idle time, and promote a more synchronized operation throughout the garment manufacturing process. The modular layout in lean manufacturing crucial role in improving overall productivity and resource utilization.

Conclusion:
The sewing line layout plays a pivotal role in optimizing the production process, enhancing efficiency, and ensuring a smooth workflow in garment manufacturing. By strategically planning the arrangement of machines, workstations, and workers, the line layout minimizes unnecessary movements, reduces waiting times, and promotes overall productivity and quality. Various types of layouts, such as straight line, U-shaped, L-shaped, S-shaped, cellular, and modular, offer flexibility to accommodate different production scales and product types. The use of specialized software like ALDEP, CORELAP, CRAFT, and CALP facilitates the creation of customized layouts tailored to specific production requirements. Ultimately, a well-designed sewing line layout not only improves resource utilization but also provides a foundation for efficient production, quick order setup, and adaptability to changes in manufacturing processes and product styles.

References:

1. https://textileengineering.net/plant-layout-in-garment-industry/
2. https://apparelresources.com/business-news/manufacturing/basics-of-machine-layout-in-sewing-line/
3. https://www.onlineclothingstudy.com/2018/01/what-is-line-layout-in-garment-industry.html
4. https://www.textileschool.com/amp/8953/factory-layout-of-apparel-industry/
5. https://www.advancetextile.net/2023/10/line-layout-in-garment-industry-types.html

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Mazharul Islam Kiron

Founder & Editor of Textile Learner. He is a Textile Consultant, Blogger & Entrepreneur. He is working as a textile consultant in several local and international companies. He is also a contributor of Wikipedia.

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