Process analysis of clothing production
Process management work can be divided into three stages: process analysis, process formulation and process implementation. There are generally two situations when garment companies conduct process analysis. One is process analysis based on customer order requirements or incoming samples and materials; the other is process analysis when designing products by themselves based on market demand. Process analysis is the basic basis for process design.
1. Technical requirements of products
1. The basic performance of raw and auxiliary materials must first clarify the product name, product number, specification, design, color, color number and Physical and chemical properties, such as color fastness, shrinkage, heat resistance, etc.
2. Product model series and name. The product model series and name must be consistent with the requirements of the product request agreement or design assignment letter or production notice and physical sample.
3. Product specifications and size requirements: Clarify the measurement system; the shape and specification requirements of product parts; what is provided is the size of the human body, the size of the finished garment, and the measurement method of the specifications and sizes of each part of the product.
4. The means of product processing and manufacturing, such as the special machines and equipment used, and the technical means used.
5. The process combination method of the product, such as the installation of parts, the sewing requirements of each part and the combination sequence of all parts, etc.
6. Is the standard adopted by the product a national standard, a ministerial standard or a standard formulated by the enterprise itself?
7. Quantity and matching: Whether the quantity of each box, specifications of each grade, and color matching are consistent with the total number requirements.
8. Trademarks and other signs: What kind of trademarks, hangtags, size signs, ingredient signs, washing instructions and other signs should be used, and the specific regulations and placement locations of code names. The contents indicated by various signs are consistent with the requirements.
9. Ironing methods and requirements: Ironing tools used and ironing methods and requirements for each part.
10. Packaging requirements: Packaging methods and materials used in packaging; folding methods; packaging specifications, quantity, packaging materials, logos, etc.
11. Other special requirements usually refer to requirements and quality evaluation indicators that are beyond the scope of normal standards.
2. Technical standards for clothing products
(1), quality standards
my country’s clothing quality standards are divided into national standards, ministerial standards, and enterprise standards Level three. The contents of clothing quality standards include:
1. Standard name
2. Scope of application
3. Specification series include
4. Material regulations
5. Technical requirements
6. Grade classification regulations
7. Inspection rules
8. Packaging and marking, transportation , Storage regulations
(2) Indicators of clothing quality technical standards
1. Quality score
2. Quality grades are divided into excellent, first class, Category II, Category III, etc.
3. Qualification rate refers to the proportion of qualified products among all products.
Qualification rate = number of qualified products/(number of qualified products number of unqualified products) × 100
4. Grade rate refers to the proportion of a certain grade of product in the total number of qualified products.
Grade rate = number of graded products/number of qualified products × 100
5. Return rate is the proportion of products that are returned for reprocessing among the products submitted for inspection.
Repair rate = number of repaired products / total number of inspections × 100
6. The adjustment rate is due to defects in raw materials and bad pieces caused by sewing processing in the total number of materials required. Or the proportion in the total number of parts and pieces produced.
Film adjustment rate = number of raw materials consumed for film adjustment / normal raw material consumption × 100
Film adjustment rate = number of film adjustments / total production × 100
7. The first is the missed inspection rate of unqualified products in the front-line inspection, and the second is the missed inspection rate in the front-line inspection.
The leakage rate of unqualified products in the front-end inspection = the number of unqualified products eliminated in the back-end inspection / (the number of unqualified products eliminated in the front-end inspection
The number of unqualified products eliminated in the back-end inspection The number of qualified products) × 100
The missed inspection rate in front-end inspection = the number of unqualified products removed from back-end inspection/the number of front-end inspection × 100
8. Scrap rate
Scrap rate = number of scraps/(number of qualified products and number of unqualified products) × 100
Formulation of clothing production process
The process plan of clothing production is the technology of clothing production and product inspection Standards and the formulation of clothing technology plans can enable clothing production to meet product specifications and quality requirements, rationally utilize raw materials to reduce costs, shorten product design and production cycles, and conduct production and operation activities efficiently.
1. Contents of process plan formulation
(1) Overall production process formulation
The overall production design includes the scale of the garment factory and production varieties. The overall design table details the varieties produced by the enterprise and the distribution of personnel in each department. Equipment configuration table refers to a list of equipment required for each process according to production varieties.
(2) Formulation of production preparation process
1. Design drawings include white drawings of the front view and back view of the clothing style.
2. Domestic and domestic sales order forms are drawn up according to customer requirements, detailing customer order items and packaging requirements.
3. Production Notification: The planning department formulates a production task order based on domestic and foreign sales orders and submits it to the production department, which then arranges production.
Production Notice
Contract Object Delivery Date Month and Day Production Group Auxiliary Materials
Item Number Product Name
Fabric Insertion Color Specifications and matching delivery time
Packaging requirements
Product
Hang tag
Ribbon
Plastic bag
Carton
Carton
Biller: Defense
Sample cards are listed in the corresponding usage column.Material details list
Contract area Product name
No. Quantity
Raw materials used Accessories used
Fabric (attached) Sample Card) Lining (Sample Card Attached) Specifications S M L XL
Inseam stitching
Outer seam stitching
Zipper
Buttons
Snaps
Straps
Button eyeliner
Overlock thread
Trademark Sample
5. The test data in the raw and auxiliary material test record sheet include heat resistance, color difference, color fastness, shrinkage, etc. Based on the test data, determine the process requirements for cutting, sewing, ironing and other processes.
6. Sample review sheet This is mainly a size review and a review of the differences between the sample and the model. The data to be reviewed generally include clothing length, chest circumference, collar, sleeve length, etc. Depending on the type of clothing, the review parts are also different.
7. Quota table of raw materials and auxiliary materials. List all raw materials in the table, and you can see the difference between the quota materials and the actual materials used.
Raw and auxiliary material quota table
Item number Product name Specification
Task order number Quantity S M L XL
Raw and auxiliary material name Door width Specification Quota Materials Average material use Quota total material use Average total material use Loss and excess
Fabric
Lining
Gudging
Zipper
Buttons
Sewing
Remarks Tabulation
Tabulation date
8. First sample seal There are problems and improvement measures for the first sample garment so that improvements can be made in mass production.
(3) Process formulation in the production stage
1. Sample management The principle of sample collection and return. When receiving and returning samples, you must go through corresponding procedures, including signatures, inspections, and reviews.
2. Bed separation process requirements: meet the number of layers and maximum length specified by production conditions; improve production efficiency, reduce duplication of labor; save fabrics and facilitate layout.
3. Layout process requirements: Comply with the process requirements of clothing production; ensure design requirements; save fabrics; choose a reasonable layout method; and prevent leakage.
4. The paving process requires keeping the fabric flat; aligning the edges; reducing the tension on the fabric during the paving process, and leaving it for a period of time before cutting; pay attention to the directionality of the fabric; use The grid needles are inserted into the required parts to ensure the accuracy of the strips and grids.
5. Cutting process requirements: Choose appropriate cutting equipment; ensure cutting accuracy, that is, ensure the shape or size of the garment pieces; reasonably control the cutting temperature.
6. The inspection process requires inspection of the size and shape of the important parts of the cut piece from the sample, and whether the deviation is within the allowable range; the deviation of the first and last layers of the cut piece Whether it meets the requirements; whether the cuts and positioning holes are drilled accurately, and whether there are any missing holes; if there are fabrics that require strips and patterns, check whether the corresponding pieces can match the stripes and patterns; check the edges of the cut pieces Check whether there are burrs or damage, and whether the piece needs to be replaced; check whether the cut piece is round and smooth, and whether there is any cutting phenomenon.
7. Numbering process requirements: the typed handwriting is clear and durable; the numbering part is accurate; suede fabrics are in the form of labels; linings generally only need to be marked with specification numbers.
8. Bonding process requirements: Use appropriate bonding equipment and tools; the cut pieces will have no aurora or bubbles after bonding, and the peeling strength will be high; consider the performance of the fabric itself when bonding.
9. The production and processing process flow is the basis for formulating the production process. It is also the technical data necessary for arranging the assembly line and configuring personnel, as well as preparing and installing process equipment.
10. Production process sheet is used for the quality requirements of specific specifications and parts of clothing.
11. Process card is the embodiment of the specific process of the overall process regulations in clothing production, the details of the technical specifications of processed products, and the basis for quality control.
12. Process quotas include quota standards for the cutting process, sewing process quotas, locking process quotas, and ironing and packaging process quotas.
13. The ironing process requires different process parameters to be determined according to the different properties of various fabrics, that is, the pressure, temperature, humidity and time must be appropriate; according to different production processes and quantities, select the appropriate matching ironing Ironing tools and auxiliary tools; the samples are processed according to the order of ironing different types of clothing to avoid phenomena such as aurora and ensure the consistency of the product; operate special equipment correctly.
14. Product quality inspection form. Recording the intermediate sampling inspection and final product inspection to avoid repeated mistakes is an important step for garment factories to improve product quality.
15. Finished product acceptance rate includes acceptance of both quality and quantity. According to the relevant contents of the order contract or product design task book, the ordering unit and the production unit shall jointly conduct quality acceptance and count the quantity.
16. Cost calculation sheet When accounting for finished garments, in addition to main and auxiliary materials, cost calculations should also consider worker wages, equipment loss, packaging costs, water and electricity bills, product processing fees, etc.