Sewing Process Research Articles

Analisis Postur Kerja menggunakan Metode Rapid Upper Limb Assesment (RULA) dan Ovako Work Posture Analysis System (OWAS) pada Awing dan Son

Awing and Son is a company that produces songkok. Based on observations that have been made, the songkok sewing process is the production part that has the highest level of complaints among other production parts. This research was conducted to identify workers' musculoskeletal disorders and provide recommendations for improvement. This research revealed that by distributing the NBM questionnaire, there were several complaints experienced by workers in the songkok sewing process. Then an analysis was carried out using the RULA and OWAS methods, this method is a method for disseminating and disseminating worker attitudes that can cause musculoskeletal disorders. The research results showed that the RULA method obtained a score of 5 with a risk level of 3, which means that corrective action needs to be taken immediately, while the OWAS score was 3 with a risk level of 2, which means that corrective action can be taken at a later date. Based on these results, proposed improvements can be made by upgrading the adjustable chairs in carrying out work.

Design and Realization of Wearable Textile Slotted Waveguide Antennas.

The design of wearable antennas presents a challenge from multiple perspectives, as they must meet technical requirements and satisfy safety standards while also being suitable for integration into clothing and aesthetically pleasing. In recent years, the development of conductive fabrics has, in many ways, allowed for significant progress in the manufacturing of wearable antennas, and in previous work, we developed textile slotted waveguide antennas using conductive textiles and traditional sewing processes. However, various aspects of the design and realization of such antennas remain challenging. In particular, this work investigates the issue of using foam-based molds, which enables the realization of thin, flexible, wearable antennas, as well as the issue of antenna feed, specifically the transition from a classic coaxial transmission line to a waveguide. The design of the transition was focused on simplicity and robustness, due to which we limited the number of degrees of freedom in the design process in order to achieve a structure suitable for mounting on textile waveguide antennas. In addition, the antenna design procedure and the body-channel model were considered in order to optimize the performance of the antennas and the wireless body-centric system itself. Several prototypes of different kinds were developed in the 5.8 GHz ISM band, confirming the feasibility of the proposed concepts through experimental results.

Implementing circular economy principles in the apparel production process: Reusing pre-consumer waste for sustainability of environment and economy

Environmentalists, the government, and the factory have always been more concerned with the inevitable pre-consumer waste produced by the apparel sector. The sustainable management of this enormous waste has received substantial attention from researchers. This study aims to experiment with a fresh approach to circular fashion, applying the circular economy principle of ‘reusing’ to manage the pre-consumer waste sustainably generated in the cutting section of the apparel industry. A specific style (boy’s t-shirts) has been assessed to trace, gather, classify and quantify the reusable cutting waste produced in a factory located in Dhaka, Bangladesh, to introduce circular fashion (toddler t-shirts) and integrate circularity practices in the existing production process. It has been found that approximately 2238 pieces of circular products (CP) can be produced from the 218.6 kg surplus fabric, 212.13 kg reusable cutting waste and 210 reusable rejected cut panels. The approach followed in the study has presented the shortest loop of the circular economy consisting of the stages of gathering, sorting, redesigning, re-cutting, and sewing process. The investigation further demonstrates that, concerning ecological sustainability and economic feasibility, the direct reutilization of pre-consumer waste of cutting sections could prove more efficient than recycling, landfilling, or incineration.

Implementation of rapid entire body assessment and anthropometry methods in conveyor design

The packaging station is one of the stations needed to produce the product. The workers in this station are still doing the process manually. The packaging station has several processes, namely the weighing process, the sewing process, and the moving process of the finished product by manually lofting the sack from the sewing machine to the pallet. The moving process has three activities holding, lifting, and moving. Workers who work manually often complain of pain felt while working, so they are at risk of experiencing musculoskeletal disorders. Accordingly, it is important to analyse the work posture to determine whether improvements must be made. The Rapid Entire Body Map (REBA) analyses the work position. Analysis of work posture is moving the product. The REBA method's posture assessment results are 8 for holding, 9 for lifting, and 10 for moving. From the results, it can be categorized as a high-risk level, and immediate improvements are needed. The improvements were made by designing a conveyor from the sewing machine to the pallet using the Anthropometric method with dimensions of 100cm, width of 65cm, and height of 113cm.

The Effect of Fabric Structure and Ultrasonic Welding Process on the Performance of the Spunlace Surgical Gowns

This study investigates the effects of fabric properties and ultrasonic welding on the performance of surgical gowns. For this purpose, eight spunlace fabrics with different structural properties were provided. First, the fabrics’ thickness, tensile strength, elongation at break, air permeability, drape behavior, and surface friction properties were investigated. Then the fabrics were sewn with the ultrasonic sewing machine. Afterward, the sewn fabrics’ seam strength, air permeability and drape behavior were tested. The results were statistically evaluated. Based on the data obtained, a detailed comparison was made between the fabrics with respect to the expectations of the surgical gowns. The higher the polyester content in the fabric, the higher the fabric strength, seam strength and air permeability. However, viscose-rich fabrics have a softer hand and are easier to drape compared to polyester fabrics. Moreover, sewing process leads to a decrease in the drape and air permeability of the fabrics.

Reducing Manufacturing Lead Time With Lean Manufacturing Approach Case Study: CV Suho Garmindo

The purpose of this study is to reduce the Lead Time Manufacturing of mask products at CV Suho Garmindo. At this time it is known that Lead Time Manufacturing is influenced by Non-Value-Added activities and Necessary Non-Value Added activities in which there are several wastes that occur, these activities include the temporary storage process in the loading section, the process of reworking defective products and the transportation process. The method used is Lean Manufacturing, the tools used are Value Stream Mapping (VSM) and Process Cycle Activity (PAM). Value Stream Mapping is used to identify activities that have a cycle time greater than the takt time, followed by Process Cycle Activity mapping to analyze activities that are Non-Value Added activities. Furthermore, NVA activities are analyzed with 5W1H, and 5 why's tool to find out the root of the problem. Based on the research results from 126.1 minutes of lead time process 110 minutes is a non-value added activity. The rework process is identified as having the largest value of contributing lead time, so rework must be eliminated. After it is known that the root cause of the rework process is due to the ineffectiveness of the sewing process (bottleneck occurs), then for improvement the author proposes the needs of the available machines and man power. The changes are the number of machines from 9 to 10, sonday operators from 2 people to 1 person, finished stick operators from 2 people to 1 person, and funnel operators from 2 people to 4 people. Furthermore, the optimal layout improvement based on production flow is described. Due to research limitations, this research did not reach the implementation stage. So with the change in the number of machine requirements and available man power, it is expected that the rework process will be reduced so that the Manufacturing Lead Time can be reduced.

Chinese Folk Embroidery Bellyband: The Intersection of Loving Symbol, Emotional Release, and Spiritual Needs

This paper analyzes the Chinese folk children’s and adult women’s bellyband, in order to explore it’s cultural connotation and artistic characteristics, and dig out useful elements for modern clothing design. This paper adopts the research methods of literature analysis, physical investigation, and modern works analysis. Through the analysis of the children’s bellyband, mainly by its summarized origin and customs, we believe that the bellyband not only has practical function and rich artistic elements, but also is the carrier of thick family love and has reference value for modern children’s clothing design. For the adult female bellyband, through the analysis of the traditional culture from the perspective of emotion, this paper believes that the shape of adult female bellyband is constrained by feudal etiquette, but its sewing process reflects women’s wisdom. At the same time, the color matching and pattern composition of bellyband are the expression and catharsis of women’s emotion. Based on this, this paper puts forward suggestions for modern clothing design, innovating the embroidery and patchwork process of bellyband, bionic modeling design. We believe that the embroidery technology, patchwork technology and pattern cultural connotation of bellyband can be combined with modern fashion design.

Proposed Design of Sewing Process Improvement to Minimize Polyester Technical Sportswear Product Defect at PT. X Based on The DMAIC Method Approach

Various companies want to improve product quality and process speed for customer satisfaction in the current era, including PT. X. Problems at PT. X is the number of defects that exceed the company's tolerance limit. The methodology used is a structured DMAIC method to identify the root causes of defects and resolve them. This study aimed to reduce defects in sportswear products caused by problems in the sewing process. The results showed that the problem in the sewing process was due to the process performance that still did not meet the standard process requirements, so the resulting output did not match the company's specifications. Therefore, it is necessary to design an alarm timer integrated with the sewing machine to minimize the frequency of defects in the sewing process. The design of the alarm timer uses the Reverse Engineering design method, which can minimize defects in the sewing process and increase the capability of the PT. X process.

Designing Software to Analyze Sewing Process of Industrial Knitted Products

In the textile industry, garment manufacturing contains four major processes containing cutting, sewing, finishing, and packaging. Sewing is the most crucial and intricate section, dealing with a large number of varied operations. A successful sewing process needs to be optimized regarding different factors, including time, sewing equipment, and skilled workers. Assembly line flow is combined by a set of operations with a particular sequence. The utmost importance of all garment industry is to arrange the workstations to minimize the number of employees in order to produce at the best productive rate with the most reasonable cost, shortest time, and satisfying quality. In most garment factories, the production lines are balanced using the empirical judgment of the line managers. For the whole process the data of production time at each step, labor productivity, proper choices of equipment were always needed to calculate line efficiency. As far as the issue is concerned, there has not been an academically sewing process analyzing software providing adequate data of sewing motions and sewing time as the credible input for the line balancing tasks. Towards this goal, this paper presents the results of research on optimizing academically self-built software to analyze the sewing process of knitted products applied to industrial production using Java programming language on Google tools. The results achieved by the software are not only to analyze sewing products and the technological sewing process, calculate the sewing time on the machine but also analyze the sewing activities of workers into manipulations, movements, and motions to calculate the preparation time for two typical knitted products, namely, Polo-Shirt and T-Shirt with the case studies at General Textile Garment Joint Stock Company Hanoi and Star Fashion Company Limited.

Motori za šivaće mašine koji štede energiju

During the current year the costs of natural gas has raised about 10 times, electricity prices have increased the similar dramatic way. However, textile industry still widely uses old generation machinery which consumes a lot of energy. New sewing machines in the market are available with two kinds of motors - traditional clutch motors and advanced servo motors. The old type clutch motors use maximum energy all the working day while the machine is switched on. The energy consumption of the servo motors depends on sewing speed and time. When the sewing process is stopped, servo motors operate in stand-by mode. Servo motors ensure to the sewing machine up to 70% less energy consumption than traditional clutch motors. They also ensure 15-30% higher work efficiency. The servo motors for sewing machines are widely available in the marker. The replacement of clutch motors to servo motors on the sewing machines is not complicated process.

Manufacturing of near-net-shape composite parts using Tailored Fiber Placement preforms

This paper demonstrates the feasibility of manufacturing a light and low cost near-net-shape vertebra from Tailored Fiber Placement (TFP) preforms. The TFP preforms were produced flat and sewn together at the ends by a classic sewing process. Low pressure Vacuum Assisted Resin Transfer Molding (VARTM) was used for the consolidation and impregnation of the preforms. The molding strategy was oriented towards the use of silicone conformers to ensure a compaction that well fits the preform despite its imperfections. The resulting part required a light finishing. The mass was reduced by 40% and the manufacturing cost by 76% compared to the original part.

RESEARCH OF VARIABLE PARAMETERS OF NEEDLE THREAD TAKE-UP MECHANISMS AND DEVELOPMENT OF RECOMMENDATIONS FOR ADJUSTING MULTI-THREAD CHAIN STITCH SEWING MACHINES

The purpose of this research is to develop specific recommendations for optimizing the adjustment of the thread take-up mechanisms of typical chain stitch sewing machines based on the analysis of the thread take-up process. These recommendations are intended to help manufacturers and machine operators achieve maximum productivity and increased product quality, while taking into account the specific technological parameters of the operations performed on these machines. The research is aimed at increasing the efficiency of the sewing process, reducing machine setup time, and improving the overall result of the technological process in the sewing industry. The research uses an analytical method of determining and investigating functions of the actual thread take-up as the instantaneous sum of sections of the take-up contour when adjustable parameters of the mechanisms are changed, taking into account accepted assumptions. In the research, an analytical method was used to determine functions of the actual thread take-up as the instantaneous sum of sections of the take-up contour, taking into account the change in regulated parameters of the mechanisms. At the same time, assumptions were made that has simplified analysis and modelling of this process with sufficient accuracy of calculation results. The scientific novelty of this research lies in discovery of new relationships and establishment of regularities that determine influence of adjustable parameters on the nature and scope of the thread take-up function in chain stitch machines. Further re-search in this area can be aimed to the development of more efficient methods of adjustment and optimization of needle thread take-up mechanisms, as well as to the implementation of new technologies in pro-duction to improve productivity and quality of sewing operations. The obtained results became basis for the development of nomograms for determining the optimal values of adjustable parameters for needle thread take-up mechanisms of typical flat chain stitch machines, taking into account technological parameters of specific operations. These nomograms allow operators and manufacturers of sewing machines significantly simplify adjustment of these mechanisms when using operational equipment or when switching to other technological operations. The obtained results can be applied directly in production during adjustment or repairing of specified ma-chines to increase their productivity by reducing adjustment time and for improving the quality of the technological process.

Study on improving the sewing process by applying the QRCI method in the automotive industry

The aim of this paper is to analyze and resolve the non-conformities identified by the internal quality control for the studied product, "Insert the front door side panel". The paper presents the way to identify the causes of non-conformities in the manufacturing flow, by analyzing the way of carrying out the activities and the reference documents within the workstations where the non-compliant products were manufactured. Because the problem was identified in time, nonconforming parts were not delivered to the customer, thus avoiding a complaint from him. An internal QRCI was opened to solve the problem. If the nonconforming parts were delivered to the customer and the customer filed a complaint with the supplier, a thorough 8D analysis was required.

STUDY ON FASHION DESIGN STUDENTS' DIFFICULTIES IN THE 2018 EXHIBITION AND FASHION DESIGN AND DEMONSTRATION COURSES AT THE STATE UNIVERSITY OF MALANG

Fashion has become a part of modern society. Fashion designers show today's fashion works through activities such as exhibitions. The Bachelor of Fashion Education and Diploma of Fashion Design, Faculty of Industrial Technology, State University of Malang, hosted a show as a part of the Exhibition and Fashion Design and Demonstration courses. Students who participated reported problems at certain stages of the exhibition process. This study aimed to analyze these difficulties using a quantitative approach descriptively. Questionnaires were used for the data collection process with 58 samples. The results suggested that the main problem lay in production design and inspiration. Students' design challenges were material choices, storyboard creation, design principles application, and ideas generation. During the fashion production phase, a difficulty occurred during the sewing process and creating an action plan. The main organizational problem for students was cooperation with internal committees at the organizational stage.
 Keywords: exhibition, difficulty, fashion creation, demonstration

Quality Control Design to Reduce Shoes Production Defects Using Root Cause Analysis and Lean Six Sigma Methods

PT. Kharisma S.F is a company that produces sporty shoes with the Eagle, Nevada, and Fladeo brands. PT. Kharisma experienced a defect in the production process, which occurred in the sewing process and assembly process. However, the most common disability experienced by PT. S.F's charisma is a defect in the sewing process. This research focuses on the inspection of the production of Eagle brand shoes. With these problems, it is necessary to carry out quality control, which is useful for regulating the various products produced so that they can have good quality. To determine the level of a defect in the DPMO value and sigma value, to find out the various factors that cause the high level of product defects, and to provide suggestions for improvement and quality control to reduce the number of product defects, Root Cause Analysis (RCA) and Lean Six Sigma methods were used. Data were obtained from the company for three months and from 6 respondents to identify waste. From the results of research conducted. It can be seen that the factor that most influences the length of waiting time in production is the human factor. The highest identification of waste is defects. There are two types of defects, namely sewing defects and assembly defects. As for alternative improvements to reduce the number of defects, namely checking machine parts on the production floor with a checklist every day and replacing machine parts that are damaged or have expired, and providing regular training to operators scheduled once every three months.

Hak Kepemilikan Sisa Jahitan Ditinjau Dari KHES

Sewing is the process of putting together pieces of fabric that have been cut based on a pattern. The sewing technique used must be in accordance with the design and materials, so that the sewing results are good and of good quality. The steps taken in the sewing process are: Prepare the sewing tools needed, such as sewing machines, hand needles, pins, pendedels, and irons. This research is a field research that directly takes data from the research location by using data sources, namely primary data and secondary data. The data collection used in this study is in the form of in-depth interviews (in-dept interviews) directly to tailors and customers. The time to conduct this research is about 2 months and the location of this research is in Hutagodang Muda Village, Siabu District, Mandailing Natal Regency. The subjects of this research are Tailors and their Customers. The results showed that the implementation of the ownership rights for the remaining stitches in Hutagodang Muda Village, Siabu District, Mandailing Natal Regency contained a lack of understanding of the law regarding the remaining stitches between the tailor and the customer, because the tailor did not return the remaining stitches to the customer measuring 1 meter, and this tailor processed the stitches. back the remaining stitches into a stitch, such as shirts, footwear, and hijab brooches, and she took advantage of the remaining stitches. In the Review of the Compilation of Sharia Economic Law on Ownership Rights of Remaining Stitches in Hutagodang Muda Village, Siabu District, Mandailing Natal Regency, where the ownership rights for the remaining stitches, if the customer gives or allows the remaining stitches to be owned by the tailor, the tailor has the right to rework the remaining stitches. that. However, if the customer does not give the remaining stitches to the tailor, then the tailor has no right to reprocess the remaining stitches.

Prediction of the sewing standard time based on process difficulty coefficient

In garment production, the standard time is a unit widely used for production planning and calculating cost. It is very difficult to prepare manufacturing plans, short term and long-term forecasts, pricing, and other technical and managerial activities in a garment company without true standard time data. Therefore, standard time prediction as the core of standard time quota management is directly related to economic accounting, production schedule control, resource optimization, production cycles shortening, cost control and product quotation. The sewing process can be regarded as the most critical step for the entire garment production, substantially completing the shape of the garment. To achieve fast and accurate sewing process standard time prediction, this paper established the evaluation indicators for sewing process difficulty, obtained the weight of each expert to indicators analysed with analytic hierarchy process, and made group utility function to calculate the difficulty coefficient. The relationship between the sewing processes standard time and the difficulty coefficient was determined to predict the unknown standard time by curve fitting. The effectiveness and usability of this method were verified by examples. The results demonstrated that the proposed method could be a good alternative to existing prediction methods.

Prediction of the sewing standard time based on process difficulty coefficient

In garment production, the standard time is a unit widely used for production planning and calculating cost. It is very difficult to prepare manufacturing plans, short term and long-term forecasts, pricing, and other technical and managerial activities in a garment company without true standard time data. Therefore, standard time prediction as the core of standard time quota management is directly related to economic accounting, production schedule control, resource optimization, production cycles shortening, cost control and product quotation. The sewing process can be regarded as the most critical step for the entire garment production, substantially completing the shape of the garment. To achieve fast and accurate sewing process standard time prediction, this paper established the evaluation indicators for sewing process difficulty, obtained the weight of each expert to indicators analysed with analytic hierarchy process, and made group utility function to calculate the difficulty coefficient. The relationship between the sewing processes standard time and the difficulty coefficient was determined to predict the unknown standard time by curve fitting. The effectiveness and usability of this method were verified by examples. The results demonstrated that the proposed method could be a good alternative to existing prediction methods

Building the Database on Software for Analyzing the Sewing Process of Knitted Products Applied in Industrial Production

Industry 4.0 significantly has changed the operating processes of traditional businesses. Technology, digital, and artificial intelligence (AI) applications have been put into practice to increase the effectiveness of corporate governance around the world. To be able to firmly integrate into the regional and global economy, general Vietnamese businesses and garment businesses, in particular, need to improve their management capacity and optimize both quantity and quality of products. Towards this goal, this paper presents the results of research on building a database on software to analyze the sewing process applied to industrial production for two groups of knitted products, namely polo shirt and t-shirt, the software uses Java programming language on Google's tool. The content of the topic has practical significance, aiming for industry, innovation, and infrastructure.

INNOVATION IN SEWING SEWING PROCESSES

The article provides insights into the innovative processes of teaching students to embroider by hand and machine, which is one of the types of folk crafts.