The document provides details on the machine requirements for manufacturing trousers. It discusses 15 key steps in the trouser manufacturing process, from pre-production to final quality auditing. It then describes 9 specific machine types needed, including fabric inspection machines, marker planning machines, fabric spreading machines, cutting machines, sewing machines, washing machines, pressing and ironing machines, thread trimming machines, and boiler machines. Key details are provided on popular brands and models for each machine type.
The document provides details on the machine requirements for manufacturing trousers. It discusses 15 key steps in the trouser manufacturing process, from pre-production to final quality auditing. It then describes 9 specific machine types needed, including fabric inspection machines, marker planning machines, fabric spreading machines, cutting machines, sewing machines, washing machines, pressing and ironing machines, thread trimming machines, and boiler machines. Key details are provided on popular brands and models for each machine type.
The document provides details on the machine requirements for manufacturing trousers. It discusses 15 key steps in the trouser manufacturing process, from pre-production to final quality auditing. It then describes 9 specific machine types needed, including fabric inspection machines, marker planning machines, fabric spreading machines, cutting machines, sewing machines, washing machines, pressing and ironing machines, thread trimming machines, and boiler machines. Key details are provided on popular brands and models for each machine type.
The document provides details on the machine requirements for manufacturing trousers. It discusses 15 key steps in the trouser manufacturing process, from pre-production to final quality auditing. It then describes 9 specific machine types needed, including fabric inspection machines, marker planning machines, fabric spreading machines, cutting machines, sewing machines, washing machines, pressing and ironing machines, thread trimming machines, and boiler machines. Key details are provided on popular brands and models for each machine type.
TOPIC : - MC REQUIREMENTS FOR TROUSER MANUFACTURING
SUBMITTED TO:- MR. JAYANT KUMAR
SUBMITTED BY:- AAKASH (BFT/19/867)
We would like to express my special thanks of gratitude to my teacher Mr. Jayant sir who gave us the golden opportunity to do this wonderful assignment, which also helped using doing a lot of Research and we came to know about so many new things we are really thankful to him. Secondly we would also like to thank our parents and friends who helped us a lot in this project within the limited time frame. CONTENT ❖ PROCESS OF MANUFACTURING TROUSER The process of trouser manufacturing when done by a full-package manufacturer involved the following processes.
They follow these steps to manufacture trousers (listed in the sequence of occurrence) -
1. Pre-production processes 2. Selection of fabric and trims as per the buyer specification 3. Procurement of fabric, trims, and accessories 4. Storage of fabric and trims in warehouse 5. Quality checking of fabric and trims 6. Pattern development (Done in the sampling stage) 7. Marker planning, fabric spreading, and cutting 8. Ticketing and bundling of cut components 9. Trouser stitching process 10. Quality checking of stitched trousers 11. Washing 12. Finishing 13. Folding and Packaging 14. Final Inspection and quality audit 15. Delivery of shipment
1. Pre-Production Process Before starting bulk material sourcing and bulk cutting, pre-production processes are involved. Like trouser sample development and sample approval. Size set samples and PP samples are developed. A trouser manufacturer can start bulk cutting after getting approval on the PP sample. 2. Selection of fabrics, trims as per the buyer Depending on the product detailing and product specification, factory selects fabrics. These activities are performed by the merchandising team. You have many options for fabrics - cotton, viscose, polyester-cotton, wool, linen fabrics. 3. Procurement of fabric, trims, and accessories Factory prepares a bill of material according to the material consumption and order volume. The sourcing team involved in sourcing of fabrics and other items. 4. Storage of fabric and trims in warehouse After the procurement of raw material, all raw materials are to be kept in a proper place that is in a storage-area/warehouse with ambient temperature, humidity required for the fabrics, and other raw materials. 5. Quality checking of fabric and trims The fabric inspection is done by laying it on the inspection table against the light. Fabric inspection and approval of fabric are done before cutting process so that unevenness in colour/shade or any other faults if any visible in the fabric are eliminated. The same level of checking is to be followed for trims and accessories. 6. Pattern making and grading Simultaneously after the approval of the order, pattern master is assigned to make patterns that will go for further marker planning and cutting department for production. Trouser patterns can be made manually or by using a CAD system. After pattern making, grading of the patterns is done for all sizes. 7. Marker planning and cutting A marker is commonly done by large thin paper that holds all the size of pattern pieces for a specific style of garments. Marker is the perfect way to reduce fabric wastage. The marker gives actual guidelines for completing the flawless or correct fabric cutting. Marker making can be done in both ways like manually and computerized methods. 8. Fabric Spreading & Cutting Spreading is a preparatory operation for cutting. The main aim of the spreading process is to lay the several fabric plies essential for the production process to the marker length without any tension on the fabric. The lay height depends on order size, fabric characteristic, capacity of the spreader, cutting method and equipment used. The preference of a mode of spreading will influence the cost of spreading as well as finished garment quality. 9. Ticketing and bundling of cut components Whenever the bundling system is used, it is accompanied by tickets or bundle tickets. It gives fundamental information about the work such as the style number, the size of the garment, the number of garments in the bundle, and the date issued. 10. Trouser stitching process The next process is the stitching of trousers using sewing machines. Cutting bundles are moved to the sewing floor and loaded to sewing lines as per the loading plan. In a line, sewing machines of different types are arranged as a vertical line to assemble the garments. The sequence of types of sewing machine arrangement depends on the sequence of assembling operations. The number of sewing machine arrangements per line may be up to 60-70 depending on the design and output quantity of trousers.
11. Quality checking of stitched garments
Inline quality checking - Inside the sewing lines, quality checkpoints are kept. Normally, after making each trouser part, stitching quality is checked by a trained quality checker.
12. Washing of trousers
Washing is an important process in trouser manufacturing. For cleaning and adding softness to the trouser. Washing is done using mild detergent. Industrial washing machines are used for trouser washing. After washing, the garments are hydro extracted to remove excess water and after this, these garments are dried in tumbler dryer.
13. Finishing process (pressing and ironing trousers)
In the finishing stage, thread trimming is done. 100 percent of the trousers are checked by the quality checkers. If stains are found on the fabric, stains are removed using spotting workstations. Then individual trousers are pressed by steam presses on a vacuum table to remove wrinkle marks. Pressman follows pressing instruction.
14. Folding and Packing of trousers
After the final inspection, the trousers are folded. Hand tags are attached. As per packing requirement pieces are poly packed. Then trousers are sorted by color-wise, size ratio wise, bundled and packed in the cartoon. 15. Final audit of packed trousers Internal inspection is not enough to consider the packed garment for ensuring the quality of the trousers. Buyers send 3rd party quality auditors (for shipment inspection). Packed garments are audited by 3rd party auditors following the AQL standard set by the buyer.
Fabric Inspection Machines are designed to check weaving, knitting defects and shade variations in fabrics. The fabric Inspection method allows you to inspect and make necessary markings for Quality Control in the manufacturing process. NAME OF MACHINE :- Ramsons Fabric Inspection Machine RFI 01
BRAND NAME :- RAMSONS
PRICE :- APPROX 1.30 LAKHS PER UNIT FEATURES :- - Extra width for wide fabric material, suitable for any fabric material under 82 width. - The speed of the roller and the rocker has been adjusted and is controlled by control box. - Inverse rolling direction for rolling back the problematic fabric material - With movable wheel for moving easily.
) A traditional printer uses a toner to print multiple dots of ink onto the paper or material being used. In addition, a plotter printer can be used to print on a wide-variety of materials, not just paper.
MACHINE NAME :- IPF PRO540S Plotter Machine.
BRAND :- RISHABH SI 721 MODEL :- IPF PRO540S.
PRICE :- APPROX Rs. 4 LAKHS PER UNIT.
FEATURES :-
Cutting plotters use knives to cut into a piece of material (such as paper, mylar or vinyl) . ▪ FABRIC SPREADING MACHINE Automatic Spreading machines are used in the unwinding of large rolls of fabric. When using industrial machines and tools to produce garments, the fabric is often ordered in giant rolls and a spreading table is often used in order to evenly roll out and spread the fabric so that it can be cut for each garment piece.
MACHINE NAME :- Fully Automatic Fabric Spreading Machine ( MH1
MASTER HOME TEXTILE ) BRAND :- RGM MACHINES PRICE :- APPROX Rs.1.18 LAKHS FEATURES :- Electronic edge control responsive to variable speed Automatic stop with safety sensors in case of emergency Multi length spreading modes Automatic pre-centering of material beginning during threading Variable speed control at forward/backward turns «Save Time» No cloth stop function Ply counter Programmable lay length and end allowance settings Four-wheel drive with wheels ▪ CUTTING MACHINE Cutting is a preproduction process of separating a spread into garment parts that are of precise size and shape of pattern pieces on a marker. Portable Cutting Machines: Portable knives can move to and through a spread by an operator.
MACHINE NAME :- PHLPS Industrial Straight Knife Cloth Cutting Machine 550W PLS 8" BRAND :- PHLPS PRICE :- Rs. 22,329 FEATURES :- Weight : 10 Kg Type of Product : Cloth Cutting Machine Voltage : 220 V Model No : PLS 8" Power : 550 W ▪ STICHING MACHINE A sewing machine is a machine used to sew fabric and materials together with thread. Sewing machines were invented during the first Industrial Revolution to decrease the amount of manual sewing work performed in clothing companies.
MACHINE NAME :- Automatic Juki Industrial Clutch Motor Stitch
Machine BRAND :- JUKI PRICE :- Rs 23,500 PER UNIT FEATURES :- Automatic Grade: Automatic Brand: Juki Maximum stitch length: 4-10 mm Max Stitch Length: 3.5 mm Power Source: Electric Sewing Speed: 4000 spm ▪ WASHING MACHINE Industrial washing machine manufacturing. Industrial washing equipment. +Info. Hygienic design with minimal water, energy and detergent consumption.
MACHINE NAME :- Laundry Machine
PRICE :- Rs. 1,45,000 Specification
Model
ETW 30
Capacity Dry weight Kg
30
Basket size D x L / Liters
750 x 960/423
Motor HP
Door Opening
560*360 Water Connection
25
Drain
75
Steam Consumption Kg/Hour
30
Dimensions W x D x H
1560 x 890 x 1100
Heater (Optional) Kw
▪ PRESSING AND IRONING MACHINE
Ironing is the use of a machine, usually a heated tool (an iron), to remove wrinkles from fabric. The heating is commonly done to a temperature of 180– 220 °Celsius (356-428 Fahrenheit), depending on the fabric. Ironing works by loosening the bonds between the long-chain polymer molecules in the fibers of the material. MACHINE NAME :- Trouser Pressing Machine PRICE :- APPROX Rs. 3.5 LAKHS Specifications: - Voltage: 1+N~50 Hz 230 V - Possibility to fit 1 or 2 swing - Arms ver.: 12 excluded - Electrically heated: 0.56 kw
▪ THREAD TRIMMER MACHINE
These machines are equipped with suction motor, trimming blade, table top and waste container. These machines are available in various designs. A thread trimming machines can be fixed on a table and operator can do trimming job by sitting on the chair.
PRICE :- Rs. 37,000
Features: Auto Thread Trimmer Max Sewing Speed: 4000-5000 stitch/min Max Stitch Width: 5mm Power Source: Electric Voltage: 210-240V ▪ BOILER MACHINE Boiler, also called Steam Generator, apparatus designed to convert a liquid to vapour. In a conventional steam power plant, a boiler consists of a furnace in which fuel is burned, surfaces to transmit heat from the combustion products to the water, and a space where steam can form and collect.
