Material movement is an important aspect in any manufacturing plant and so as in apparel manufacturing

plant. In any plant there are various materials which are to be constantly moved from one section to the
other and so in the apparel manufacturing plant where some or the other equipment’s or machines are
used for the movement of material. Here, I will be discussing overhead hanging system as the material
movement technology in sewing .

Technology for Material Movement in Sewing

Material movement requires a material handling system for the appropriate material movement where a good
material handling system becomes necessity and is considered for better factory performance and smooth
material flow. A right material handling system across the factory departments, reduces material
transportation time, waiting time at work and delay. In sewing department, material handling system is
designed based on the line layout, which is required for movement of bundles from one workstation to another
and also for storing. Material handling can be done by several ways such as Conventional side table where a
side bench or a side table is placed for loading cuttings and disposing stitched garments, while in a Centre
table a bench is placed in between two rows of machines, where as in some place’s trolleys, bags or bins are
used. In many unit’s overhead rail and hanger is also used for transporting materials. The equipment being
used can be classified into the following categories based on the level of automation:
Basic Level
Manual hanger system
Advanced Level
Computerized hanger system

At this stage it is also important to identify which line layout is ideal for the product type of the respective
company, also it is important to know the capacity and ability of the company, accordingly material handling
system can be identified for the material movement.

Basic Level of Technology: Manual Hanger system

Typical Work-Cycle Element:
 Pick up hanging piece
 Stitch
 check
 hang it back
 push the hanger

Manual hanger system is an evolved form of material handling and movement system in the industry, as earlier
tables and bins were used. Any Hanger system has several components such as hanger, rail, conveyor etc. and
does runs on conveyor where manual hanger system has manual conveyor and runs short distance on rails by
hand push. The steel rail/rod allow unilateral movement of hangers over the path.

it greatly reduces the labour intensity, operation personnel to improve production efficiency making full use
of the production factory space by unhindered transporting to the obligatory location. It is very light and
flexible; the fork type design is easy for the transfer of products. manual hanger system avoid fold in the
process of manual transmission, improve the quality of products.

It has the obvious advantage of floor space maximization, by allowing components and complete vehicles to
be moved safely above normal working height.it can speed
 Machinery and Equipment Required for Basic Level of Technology (Manual Hanger system):

Makes and Models Features and Specification of Machinery and Equipment

Hangers, installation technology, conveyor

1.MTS manual hanger
system
2.EURATEX

Figure 1 Manual hanger system

Advanced Level of Technology: Computerized automated Hanger System

Using automated and computerised hanger system or other computerised materials movement systems
can help in lot of ways. It has a wide range of benefits such as it reduces dependence on manpower due
to which cost, time and chances of error gets reduced, it also records the materials movements
simultaneously which helps in improving quality control. These systems can handle multiple designs and
bulk orders with better performance and with lesser errors. These systems help in allocating the resource
and work in real time and distributing the labour in efficient way. These systems help in obtaining safer,
cleaner, spacious work place which is easy to work and has uninterrupted work flow. It increases the
productivity and reduces the throughput time. Overall, these systems help in achieving better performance
in terms of production output and is easier for the manpower to work.
Some of the benefits of automatic system of material movement over manual system are as follows-
1) I t has Automatically addressable system with the ability to transport & integrate lines over bridges.
2) In this each station can be configured as per the operation to position the pcs close to the need point.
3) Real-time information can be achieved from the lines and has the Ability to connect the data on real-
time with the ERP
4) auto balancing can be done within the same operation.
5) It has a function of Accurate traceability & accountability.
6) Able to get Quality & off-standard information.
7) Easy to integrate with automatic machines.
8) Easy to integrate departments over different floors.
9) Clear visibility, to manage the line by eye. Easy to locate bottlenecks.
10) Ability to run multiple styles in one line.

Machinery and Equipment Required for Advanced Level of Technology (computerized

Hanger system):

MAKES AND MODELS FEATURES AND SPECIFICATION OF

MACHINERY AND EQUIPMENT
ETON SELECT STATION LENGTH -1500MM,
WIDTH- 500MM,
PRODUCT CARRIERS/STATION -12,
MAX. WT. PER CARRIER -2.5KG,
IDENTIFICATION RFID,
NO. OF RFID READERS PER STATION- 3,
OPERATOR TERMINAL/STATION- 1.
MAIN LINE HEIGHT- 2000-2550 MM,
MAIN LINE SPEED -20 METER/MIN,
PUSHER SPACING- 1000MM.

PRICE-2500 USD
INA EHC6R STATION LENGTH -2200MM,
WIDTH- 500MM,
PRODUCT CARRIERS/STATION -7,
MAX. WT. PER CARRIER -3.5KG,
IDENTIFICATION -RFID,
NO. OF RFID READERS PER STATION- 3,
OPERATOR TERMINAL/STATION- 1.
MAIN LINE HEIGHT- 2000-3000 MM,
MAIN LINE SPEED -15 METER/MIN,
PUSHER SPACING- 1000MM.
MICROELECTRONIC CHIP IN HANGER
POWER
SMART MRT HANGER SYSTEM STATION LENGTH -500MM,
WIDTH- 500MM,
PRODUCT CARRIERS/STATION -8,
MAX. WT. PER CARRIER -4 KG,
IDENTIFICATION- RFID,
OPERATOR TERMINAL/STATION- 1.
MAIN LINE HEIGHT- 2500 MM,
MAIN LINE SPEED -15 METER/MIN,
PUSHER SPACING- 1000MM.
Figure 2Equipment’s of an automatic hanger system
ROI CALCULATION
OPERATION BREAKDOWN OF A POLO SHIRT
 MATERIAL MOVEMENT IN SEWING FOR A POLO SHIRT

CM PRICE OF THE GARMENT(RS) 100

SEWING COST 40%0F RS 40 40
SAM VALUE FOR THE SHIRT 13
TOTAL SAM(MIN) 13
CM PRICE PER POCKET (RS) 40.00
TOTAL NO OF OPERATION 23
TOTAL NO OF WORKSTATION
REQUIRED 22

BASIC LEVEL OF ADVANCED LEVEL OF

TECHNOLOGY TECHNOLOGY
SAM VALUE FOR GARMENT(MIN) 13 11.08
MATERIAL MOVEMENT TIME (SEC) 10 5.00
TOTAL TIME TAKEN IN MATERIAL
MOVEMENT(MIN) 3.833333333 1.92
PRODUCTION PER DAY (SHIFT OF 8
HOURS) 37 43
WORKING DAYS /MONTH 26 26
NO. OF MONTHS /YEAR 12 12
PRODUCTION PER ANNUM 11520 13512.18045
CM PRICE PER SHIRT 40.00 40.00
COST OUTPUT/ANNUM 460800 540487
PRODUCTION TARGET(PCS/DAY) 43 43
NO OF WORKSTATION REQUIRED 22 22
COST OF 1 WORKSTATION 95000 1,75,000
COST OF TOTAL MACHINE (RS.), T 2090000 3850000
ANNUAL DEPRECIATION (%) 0.15 0.15
DEPRECIATED VALUE OF M/C AFTR
ONEYEAR (Z) 1817391 3347826
COST OF OPERATORS P.M 6000 6000
TOTAL OPERATORS SALARY (Y) 1584000 1584000
CM PRICE FROM TOTAL M/C (X) 10137600 11890719
CASH INFLOW (I) 8553600 10306719
ROI FOR THE FIRST YEAR, (X-Y)/Z 470.65% 307.86%
PAY BACK PERIOD (T/I) 0.24 0.37

Conclusion

In case of material movement system in sewing line, we are not having a good return of investment. For the
bulk level of manufacturing advancement in technology will give high productivity with low manpower
involvement and low cost of production with remote mode of maintenance. As per ROI calculation adlevel of
technology is very effective in terms of production and quality except initial cost of investment which is too
high.
REFERENCES
 https://marketsgazette.com/2019/10/02/global-intelligent-hanging-system-market-2019-rising-trends-
eton-sunrise-ina-clever-max-weishi
 https://www.onlineclothingstudy.com/search/label/Technology
 http://www.ina-ina.com/en/showproduct.asp?pro_id=201509190005
 https://smartmrt.com/product/smartmrt-hanger-system/
 https://www.youtube.com/results?search_query=manual+hanger+system
 https://www.etonsystems.com/en/
 https://www.indiamart.com/proddetail/manual-material-hanger-system-20718710533.html
 https://www.alibaba.com/countrysearch/CN/garment-hanging-system.html
KPI

1.REAL-TIME DATA TRACKING

2.SMOOTH MATERIAL FLOW

3.LOW MAINTENANCE COST

4.USER FRIENDLY

5.ACCURATE CONTROL OF PRODUCTION

6.EASY LOADING /UNLOADING

PLAGRISM REPORT