APPAREL PRODUCTION AND

ERGONOMICS
KIRUTHIKA K
BD/18/1094
LD-05
ERGONOMICS FOR WORKPLACE
The designing of the workplace in the garment industry
should always apply the five principles of ergonomics:
1. Ergonomic principles in designing a workplace.
2. Ergonomic principles in designing working processes.
3. Ergonomic principles in determining working time.
4. Ergonomic principles in handling material and tools.
5. Ergonomic principles in designing an environment.
Ergonomic principles in designing a workplace
• The designing of the workplace should be such that
the work performed should be either in sitting or
standing posture.
• Workplace height should be such that a standing
work can be replaced by a sitting one upon
requirement.
• There should be enough space for the operator to
stretch his legs comfortably.
• There should of armrest for the operator if the work
he is performing requires so.
Ergonomic principles in designing working processes
• While performing the operation the posture should be
such that the operator has to apply a minimum
amount of energy to complete the operation.
• The work should be organized for easy and natural
repetitions.
• Only when there is a requirement of higher force by
hand or movements standing posture is to use.
Examples of such can be cutting, pressing, etc.
• Work should be such that there is a use of both hands
simultaneously whenever possible.
Ergonomic principles in determining working time.
• Production time should be only determined for the
operator who is skilled enough for the job and has
average experience, for greater accuracy.
• While calculating the average time taken for operation
considerations should be taken for pause for handling
loads, improper body posture in work and monotony as
they seriously affect the average time due to fatigue.
Ergonomic principles in handling material and tools.
• Garment components should be placed in such a way
that there is a minimum of movement by the operator
in retrieving the pieces. By doing this much of the
valuable time can be saved.
• All the material pieces, tools, etc required in the
operation should be positioned close to the operator to
avoid bending the body on retrieval.
• There is a certain recommended limit of forces that
should be followed while performing lifting operations
under favorable conditions
Ergonomic principles in designing environment
• Whether using daylight or artificial illumination the
intensity, distribution, and type of illumination should
prevent any strain on eyes.
• Appropriate intensity, type of illumination, distribution
should be there for different operations. Such as
checking operations require a much higher intensity of
light.
• Individual sources of light should be provided for
sewing dark material and intricate topstitch.
• The minimum work area per person should be 4m2.
• Noise and vibrations should also be taken care of as
prolonged exposure to such can cause damage. For
standard value, noise should not exceed 50dB for
intellectual work, 70dB from office and similar work,
90dB for other types of work.
• Color of the workplace also plays an important role
as it gives the feeling of warmth or coldness to the
workers. There have been various studies that
proved that brighter colors have a pleasant effect on
the workers increasing their concentration, mood,
and speed of work whereas cold and dark colors
create a feeling of apathy, bad mood, and sleepiness
of workers.
• There should be proper hygienic conditions around
the workplace provided with an adequate number
of washrooms.
• Workplace should be kept clean all the time.
• Various studies have shown that music removes
fatigue among workers, reduces monotony and
anxiety at work. Thus, music can be played at
intervals to boost up the workers
 Black women jacket with lapel collar
Order : 3000

Black satin lining

Brand Label

Large sized buttons

Sheep nappa
Shell fabric (sheep nappa)

1.Front side panel (cut 2)

2.Front panel (cut 2)
3.Back side panel(cut 2)
4.Back panel(on fold )
5.Side bottom panel(cut2)
6.Front bottom panel(cut 2)
7.Front sleeve panel(cut 2)
8.Back sleeve panel (cut 2)
9. Cuff (cut 2 )
10. Collar (on fold)
Lining (satin)

1.Front side panel (cut 2)

4.Back panel(cut 2)
7.Sleeve (cut 2 )
8.Cuff (cut 2)

Lining (leather)

2.Front panel (cut 2)

3.Collar (on fold)
8.Cuff (cut 2)
5.Side bottom panel(cut2)
6.Front bottom panel(cut 2)
Research and
development
• Exploration and approval
of design SEQUENCE
Selection of
• Materials and trims are selected
OF
leather and
non leather
materials
based on the paramters like
thickness, species and finish. OPERATION
FOR GARMENT

• Net pattern
Pattern making
• Working pattern

• It is reviewed by a panel
Prototype and changes are made
at this stage itself

• Standard patterns are made either manually or

Production digitally in pattern making paper. Grading is
pattern also done at this stage, preferable in digital for
precision.

Matching and • Leather is grouped based on color

on horse shoe
Marker making • Patterns are arranged and marked
with silver pen
 STITCHING OPERATION BREAKDOWN
FRONT AND BACK PART LINING M/C USED
• Spilting
Cutting Joining centre back S/N
• Skiving
Side seam S/N
Overlocking seams O/L
Front panel Lining leather S/N
• Micro fusing sheet is
Fusing / Attctch brand label to lining S/N
used for extra
attaching
reinforcement Shell fabric
Back princess seam (FS+TS) D/N
Front princess seam (FS+TS) D/N

Assembling • Before stitching patterns are Bottom panel (FS+TS) with lining D/N
assembled
Side seams (FS+TS) S/N
Shoulder joining (SSS) S/N
Button hole front and front bottom B/N
panel
Stitching
Sleeve
operations
Sleeve and cuff lining S/N
Back and front arm joining (FS+TS) D/N
Cuff joining (FS+TS) D/N
Lining and shell fabric
Lapel shell to lining D/N
Bottom panel and top attachment D/N
Sleeve attatchment C/B
Collar attatchment D/N D/N- DOUBLE NEEDLE SEWING MACHINE
S/N- SINGLE NEEDLE SEWING MACHINE
C/B- CYLINDRICAL BED SEWING MACHINE
B/N-BUTTON HOLE MACHINE
O/L- OVERLOCK MACHINE
 • Each and every garment
Quality passes through the spection
checking table to detect any defect.

• Includes hammering,
Finishing ironing and thread
cutting.

Final • Last inspection on behalf of product

inspection manufacturing organization

Packing • Jackets are often packed in a

garment bag

• It is dispatched to
Dispatch the godown from
where it is shipped
 I N D U ST R I A L
P L A N N I N G & L AYO U T

OBJECTIVE
To plan a leather garment
industry according to the
sequence of operations listed
above with the help of the
principles of ergonomics.

WORKFORCE
The work shift is 7 hours a day
for 6 days a week, which leaves
25 working days.

TARGET
To finish 120 leather jackets
every day which targets to 3000
a month.
PRODUCT LAYOUT
I have used product layout for both , in which the whole emphasis is
given to the product that is manufactured. The object here is to
arrange machines in the order of operations that are performed.
Therefore, each work station either machine or work bench does
whatever operation on the product that follows the work done at
the preceding work station, then passes the product to the next
station in the line in which the next operation is performed.
PROS
• Smooth flow of production.
• Production process is continuous and uninterrupted, work-in-
progress is less.
• Optimum space utilization.
• Product layout ensures effective utilization of resources by
ensuring.
• Continuous supervision and control of the manufacturing
process.
• Production process is continuous, production control is
facilitated.
• Time spent for transporting materials can be minimized.
I-LINE
The simplest line is the I-line, a straight line. This is common
for very short lines or for automated lines. The advantage is
easy access from both sides for both material and operators.
he purpose of choosing one line layout over other is to
achieve best production with existing resources. In this
layout sewing machines are placed side by side.
U-LINE
The U-line is actually quite famous in lean manufacturing.
Often it is praised as the best possible line layout. This U-
shaped line is indeed quite nifty, but it is not a universal
solution for anything. The U-line is used mostly for manual
manufacturing lines. A U-line is less ideal for fully or mostly
automated lines. The main benefit exists if multiple
operators are within the “U” of the line. All the operators
are within the “U,” while the material is supplied from
outside of the “U.”
GARMENT FACTORY LAYOUT

PRE PRODUCTION DEPARTMENT

PRODUCTION DEPARTMENT

FINISHING DEPARTMENT
 PRE-PRODUCTION
DEPARTMENT NO. OF EMPLOYEES QUALIFICATION
R&D 1 main & 2 sub Skilled
Merchandising 2 Skilled
Production planning and control 4 Skilled
Sampling 2 Skilled
Leather labelling 2 Skilled
Leather & trim store 4 Semi-skilled
Assorting 3 Skilled

PRODUCTION
DEPARTMENT NO . OF EMPLOYEES QUALIFICATION
Manual pattern making 1 Skilled
Digital pattern making 2 Skilled
Cutting 7 Semi-skilled
Splitting 1 Skilled
Skiving 1 Skilled
Fusing 2 Semi-skilled
Stitching 40 Skilled

*Stitching sector has totally 40 employees targeted to completed 3 jackets per day.
 STITCHING MACHINERY
TYPE OF MACHINE NO.OF MACHINES
Single needle light duty sewing machine 5
Single needle heavy duty sewing machine 5
Double needle heavy duty machine 20
Cylindrical bed sewing machine 5
Overlock machine 3
Button stitch machine 1
Button hole machine 1

OTHER MACHINERY
TYPE OF MACHINE NO.OF MACHINES
Digital pattern making machine 1
Electric leather fusing machine 1

FINISHING
DEPARTMENT NO . OF EMPLOYEES QUALIFICATION
Inspection 3 Semi-skilled
Finishing 6 Skilled
Final inspection 3 Semi-skilled
Packaging 2 Semi-skilled
 OTHER EQUIOMENTS
NAME NO.OF EQUIPMENTS
Cutting tables 7
Computer for digital pattern making 1
Iron box and table for manual fusing 2
Hammer and table 2

OTHER D E PA R T M E N T S
NAME NO.OF EMPLOYEES
Cafeteria 6
Account department 3
Human resource and Administration 2
Electronic data processing 2
Shipping and documentation 4
First aid room 1
Cleaning and House keeping 10
Security and CCTV room 1 head and 3 sub
 Black Duffel bag
Order : 9000

Brass D- ring and adjuster

Zipper (brass metal )

Handle

Gazatte (full grain cowhide)

Strap for d- ring

Brand label

Side Strap
Shell fabric (Full grain
cowhide)

1. Outer panel(on fold 0

2. Handle (cut 2)
3. Strap (cut 2)
4. Label strip
5. Small strap (cut 2 )
6. Gazatte (cut 1)
7. Gazatte with zipper (cut 2 )

Lining (Taffeta )

1.Inner panel (on fold )

6. Gazatte (cut 2 )

Lining (Leather)

2.Handle backside (cut 2)

3.Strap backside (cut 1)
5.Small strap inside (cut 2)
Research and
development
• Exploration and approval
of design SEQUENCE
Selection of
• Materials and trims are selected
OF
leather and
non leather
materials
based on the paramters like
thickness, species and finish. OPERATION
FOR PRODUCT

• Net pattern
Pattern making
• Working pattern

• It is reviewed by a panel
Prototype and changes are made
at this stage itself

• Standard patterns are made either manually or

Production digitally in pattern making paper. Grading is
pattern also done at this stage, preferable in digital for
precision.

Matching and • Leather is grouped based on color

on horse shoe
Marker making • Patterns are arranged and marked
with silver pen
 • Spilting
Cutting
• Skiving
STITCHING OPERATION BREAKDOWN
LINING M/C USED

• Micro fusing sheet is Joining inner part and gazette S/N

Fusing /
used for extra Gazette pocket O/L
attaching
reinforcement Overlocking O/L
STRAP
Handle strap D/N
Assembling • Before stitching patterns are
assembled Sling strap with adjuster D/N
Small strap D/N
SHELL
Handle to outer body D/N
Stitching Riveting strap to shell R/M
operations
Label to outer body D/N
Gazette pocket shell and lining S/N
Attatching zipper to gazette S/N
Gazette to outer shell(with small C/B
trap and d ring )
Shell+lining+zipper C/B
Sling strap to D ring C/B

D/N- DOUBLE NEEDLE SEWING MACHINE

S/N- SINGLE NEEDLE SEWING MACHINE
C/B- CYLINDRICAL BED SEWING MACHINE
R/M- RIVETING MACHINE
O/L- OVERLOCK MACHINE
 • Each and every garment
Quality passes through the spection
checking table to detect any defect.

• Includes hammering
Finishing
and thread cutting.

Final • Last inspection on behalf of product

inspection manufacturing organization

Packing • Jackets are often packed in a

garment bag

• It is dispatched to
Dispatch the godown from
where it is shipped
 I N D U ST R I A L
P L A N N I N G & L AYO U T

OBJECTIVE
To plan a leather goods industry
according to the sequence of
operations listed above with the
help of the principles of
ergonomics.

WORKFORCE
The work shift is 7 hours a day
for 6 days a week, which leaves
25 working days.

TARGET
To finish 360 leather duffel bag
every day which targets to 9000
a month.
 PRE-PRODUCTION
DEPARTMENT NO. OF EMPLOYEES QUALIFICATION
R&D 1 main & 4 sub Skilled
Merchandising 2 Skilled
Production planning and control 4 Skilled
Sampling 2 Skilled
Leather labelling 4 Skilled
Leather & trim store 5 Semi-skilled
Assorting 4 Skilled

PRODUCTION
DEPARTMENT NO . OF EMPLOYEES QUALIFICATION
Manual pattern making 1 Skilled
Digital pattern making 2 Skilled
Cutting 15 Semi-skilled
Splitting 2 Skilled
Skiving 2 Skilled
Hammering 2 Semi-skilled
Stitching 60 Skilled

*Stitching sector has totally 60 employees targeted to completed 6 bags per day.
 STITCHING MACHINERY
TYPE OF MACHINE NO.OF MACHINES
Single needle light duty sewing machine 5
Single needle heavy duty sewing machine 15
Double needle heavy duty machine 20
Cylindrical bed sewing machine 15
Overlock machine 5

OTHER MACHINERY
TYPE OF MACHINE NO.OF MACHINES
Digital pattern making machine 1
Riveting machine 5

FINISHING
DEPARTMENT NO . OF EMPLOYEES QUALIFICATION
Inspection 4 Semi-skilled
Finishing 6 Skilled
Final inspection 4 Semi-skilled
Packaging 5 Semi-skilled
 OTHER EQUIOMENTS
NAME NO.OF EQUIPMENTS
Cutting tables 7
Computer for digital pattern making 1
Hammer and table 5

OTHER D E PA R T M E N T S
NAME NO.OF EMPLOYEES
Cafeteria 10
Account department 5
Human resource and Administration 4
Electronic data processing 2
Shipping and documentation 6
First aid 1
Cleaning and House keeping 15
Security and CCTV room 1 head and 3 sub
 LEATHER GOODS FACTORY
GROUND FLOOR

LAYOUT
1 ST FLOOR