Sapphire Textile Mills Ltd.

About Sapphire Home Textiles: Sapphire Home Textiles is one of the largest manufacturers and exporters of textile products in Pakistan. Sapphire has most modern and organized textile production setup. We have versatile stitching facility with state of the art stitching machines and capable of stitching a wide variety of woven & knitted fabrics using the chain system for efficient mass production. Specialized in a variety of stitches such as, Single Needle Lock Stitch, Zigzag Stitch, Five Thread Safety Stitch, Bar Tack Stitch, Button Hole & Button Attachment Stitch. We are specialize in a variety of Home Textile Made ups such as Sheet Sets, Quilt/Duvet Covers, Bed Skirts, Shams, Pillowcases, Comforters, Curtains, Table Covers, Aprons etc. We believe in total quality from raw material, to all stages of stitched Made-up production till delivery. Skillfully trained quality inspectors carry out quality assurance. Abstract/Summary/: Stitching is the major operations in apparel manufacturing industry. Increasing the production rate of this process without losing quality of product is major concern of production department so that shipment date could be met. For the estimation of cost of making a garment SAM value plays a very important role. On-line time study is an accurate method to determine the Standard time for operations performed on fabric.Time study is used in order to achieve rational and reasonable results for costing of Stitching operations. In the following paragraphs stitching cost has been estimated for assigned articles. Customer: Harbor Article: Flat Bed Sheet Dimensions: 70x115 Inches
Fabric Desig Ready Cut Quality n Size Size* 40x40/130x Percal 70x115 72x12 58 e 0 *with top hem of 3 & bottom hem of 1 P O Quanti ty 28800 Directi on WxL C.F 1.82 Fabric Required 52416 mtr Fabric Width 120

Operations: Three operations are used.

1- Top hem 2- Bottom hem 3- Side hem All these operations are carried out on three separate stations with the help of single needle lock stitching machine. Thread Consumption: Lock stitch length working = 72+72+115+115 = 374 Thread utilized per inch = 3.5 Thread consumed = 3.5 x 374 = 1309 =33.25 meters For 28800 pieces = 33.25 x 28800 = 957600 meters Total Thread Required = 1005480 meters No. of large cones Required = 1005480/ 5000 = 201.1 cones Thread cost = 201.1 x 193 = 38812.3 Rs. Cost of Thread per Piece = 1.347 Rs.

Time Study For Flat Bed Sheet:

1st operation Top hem Time Rating 2nd operation Bottom hem Time Rating 3rd operation Side hem Time Rating

Operator 1

Operator 2

Average time Standard time SAM

Note: For single lock stitch daily wage: 500 For single lock stitch per minute cost(SMV): 500/480 = 1.04 Rs.

1- Top hem SAM = 29.04 = 0.484 min SMV = 500/480 = 1.04 Operation cost per pc = SAM SMV = 0.484 1.04 = 0.50 Rs. For 28800 pcs = 14400Rs. No. of products processed in 8 hrs = 991 pcs 2- Bottom hem SAM = 33 sec = 0.55 min SMV = 1.04 Rs/min Operation cost per pc = SAM SMV = 0.55 1.04 = 0.572 Rs. For 28800 pcs = 16473.6 Rs. No. of products processed in 8 hrs = 872.7~872 3- Side hem SAM = 77.88 = 1.29 min SMV = 1.04 Rs. Operation cost per pc = SAM SMV = 1.29 1.04 = 1.342 Rs/min For 28800 pcs = 38649.6 Rs. No. of products processed in 8 hrs = 369.8~369 pcs

From above calculations it is clear that station # 3 is our bottle neck station. It is processing minimum number of products. We can produce only 369 completed products on a single line. Even if we increase no stations for last operation, still they cannot meet the production of their succeeding operations. But a small inventory between the stations is desireable for inspection and trimming operations.

Accessories Cost: Cost of labels = Cost of label joining with each other = Electricity cost: Machine power = 400 W Tube Lights Wattage = 40+40+14= 94 W Total Wattage = 494 ~500 W Time taken for consumption of one unit = 1KWh/ Wattage = 1000/ 500 = 2 hrs. = 120 min Cost per min = Price of one unit of power/ time for one unit = 11/120 = .092 Rs. Line Balancing:

Customer: Harbor Article: Pillow Case Dimensions: 2030 inches

Fabric Desig Quality n 3753 40x40/130 Percal 6 x59 e *with 3 hem on opening PO Ready Size 20x32 Cut Size* 21x71 Quanti ty 720 Directi on WxL C. F 0.3 6 Fabric Required 259.2 mtr Fabric Width 105

Operations: Two operations are used. 1- Opening Hem

2- Side Safety Stitching Single needle lock stitch machine is used for hemming and 5 thread safety stitching is carried out to mould it into U-shape. Thread Consumption: Lock Stitch working = 21+21=42 Thread utilized per inch for single lock stitch = 3.5 Thread consumed = 3.5 x 42 = 147 Side Lengths = 30+30 = 60 Thread utilized per inch for safety stitch = 20 Thread consumed = 20x 60 = 1200 Total thread consumed per Piece = 1200+147 = 1347 = 34.214 meters Thread consumed for 28800 pieces = 34.214 x 28800 =985363.2 meters Total thread required = 1034631.4 meters No. of large cones required = 1034631.4/ 5000 = 206.93~ 207 Cost of one cone = 193 Rs. Cost of thread consumed = 193 x 207 = 39951 Rs. Cost of thread for one product = 1.38 Rs

Time Study For Pillow Case: Ist operation Top & bottom hem Time Rating Operator 1 2nd operation Side safety Time Rating

Operator 2

Average time Standard time SAM For single lock stitch daily wage: 500 For single lock stitch per minute cost(SMV) 500/480 = 1.04 Rs. For safety stitch daily wage: 550 For safety stitch per min cost (SMV): 550/480 = 1.15Rs. 1- Top & bottom hem SAM = 20.46sec = 0.341 min SMV = 1.04 Rs. Operation cost per pc = SAM SMV = 0.341 1.04 = 0.35 Rs. For 28800 pcs = 10080 Rs. No. of products processed in 8 hrs = 1407 pcs 2- Side Safety over lock SAM = 43.05 sec = 0.72min SMV = 1.15 Rs. Operation cost per pc = SAM SMV = 0.721.15 = 0.828 Rs. For 28800 pcs = 238464.4 Rs. No. of products processed in 8 hrs = 666 pcs

Time taken by one product = 0.34+ 0.72= 1.06 min Available time = 8 hrs= 480 min Total product made in 8 hours = 452

Accessories Cost: Cost of labels = Cost of label joining with each other =

Electricity cost: Machine power = 400 W Tube Lights Wattage = 40+40+14= 94 W Total Wattage = 494 ~500 W Time taken for consumption of one unit = 1KWh/ Wattage = 1000/ 500 = 2 hrs. = 120 min Cost per min = Price of one unit of power/ time for one unit = 11/120 = .092 Rs. Line Balancing:

Recommendations/ Suggestions/ Findings: