Line Layout

A 'Line layout' can be described as the material flow from operation to operation in an assembly line from start till the end during apparel production.

In order to start with the line layout, the first thing is the understanding of the product that will be manufactured. The production steps are identified for completing the garment. The most used production system in the apparel industry is the progressive bundle system and unit production system. In the case of the unit production system, the machines are fixed and material is transported from machine to machine with an electronically controlled overhead system. The importance of line layout is more important in the case of a progressive bundle system because here the cut parts move in the production line step by step. The back and forth motion of the bundle is unacceptable and may disturb the whole line set up.

Key things to know for line layout are:

  • No. of steps of garment completion
  • Identification of each sewing machine for each operation
  • No. of machines for each operation based on line target
  • Smooth workflow between operation to operation
  • Avoidance/identification of bottleneck operation
PBS

The image explains a step-by-step movement of material from operation to operation. In this graphical representation can also be seen that each operation has a different number of machines. The number of machine for each operation is an act of balancing the line, which will be explained in the next steps. The sewing operation can be described as a particular sewing action that is involved to make a garment. The garments can only be made in a particular sequence. Each operation has specific requirements and accordingly the sewing machine is allocated. The table below shows the breakdown of basic 5 pocket jeans with an allocation of machine type for each sewing operation.

Style bulletin
Operation Breakdown of basic 5 pocket jeans

In an apparel production organization, with a predetermined line layout, the production supervisor can set up the line in the least amount of time. According to the line target and based on time and motion studies, the requirement of machines per operation is established for a balanced production line. Style change over time can be reduced by preparing a detailed line layout and doing a line set-up based on the line layout.  Line layout is an essential part of setting up a new production line. Based on it the overhead wiring, pressured air connection, installation of ironing tables, QC tables, and other fixtures are installed.   





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